1958 FORD THUNDERBIRD

FORD DIVISION FORD MOTOR COMPANY

Copyright 2009, Forel Publishing Company, LLC, Woodbridge, Virginia All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192

1958 Ford Thunderbird Shop Manual EAN: 978-1-60371-008-4 ISBN: 1-60371-008-6

Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: webmaster@ForelPublishing.com Website: http://www.ForelPublishing.com

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Note from the Editor

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Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.

GROUP

POWER PLANT

CLUTCH, CONVENTIONAL TRANSMISSIONS,

ANO REAR AXLE

CRUISE-O-MATIC TRANSMISSION

CHASSIS SUSPENSION AND UNDERBODY

STEERINO

BRAKES

GENERATING AND STARTING SYSTEMS

1958 THUNDERBIRD SHOP MANUAL

LIGHTS, INSTRUMENTS, AND ACCESSORIES

BODY MAINTENANCE AND REPAIR

DOORS, DECK LID, AND

FRONT SHEET METAL

INTERIOR TRIM, SEATS, AND WINDOWS

SERVICE

DEPARTMENT

FORD
FORD

DIVISION
COMPANY

MAINTENANCE, LUBRICATION,
AND SPECIAL TOOLS

MOTOR

SPECIFICATIONS
1958

FORD

MOTOR

COMPANY, DEARBORN,

MICHIGAN

Reprinted

with

Ford Motor Company's Permission

FOREWORD

This

manual provides

information for the

proper

servicing of the 1958 conditioning is

covered

Thunderbird. Service information

a separate

on

air

in

manual.

The descriptions

and specifications contained

in for

this manual were in effect at the time the manual was approved

printing.

The Ford Division of Ford Motor Company,

one

whose

policy

is
models at

of

continuous

improvement,

reserves the right to

discontinue

any time,

or change specifications or

design,

without notice

and without

incurring obligation.
SERVICE DEPARTMENT

FORD

DIVISION

FORD MOTOR COMPANY

1958 THUNDERBIRD
SHOP MANUAL

GROUP 1 POWER PLANT

Page

PART 1

ENGINE PART 2
IGNITION SYSTEM

1-2

1-44

PART 3 FUEL SYSTEM PART 4

1-58

COOLING SYSTEM

1-77

1-2

GROUP

POWER

PART 1

ENGINE

Section

Page

Section

Page

Section

Page
and

Description

1-2

Valve Rocker Arm Shaft

Camshaft
1-27
1-27 1-28

Bearings

1-34

2 General Engine Trouble

Assembly
1-7 1-10

Crankshaft

1-35

Shooting
3

Cylinder Heads Hydraulic Valve Lifters

Connecting Rods
Piston, Pins,
Main
and
and

1-35 Rings
1-35

Tune-Up
and

Piston Rod

and

Connecting
1-28 1-30
and

Connecting
1-37
1-38

4 Tests

Adjustments

Rod Bearings Conventional Flywheel Cylinder Block

(Engine In

Chassis)

1-11 1-11 1-12

1-12

Oil

Pump

Camshaft Lobe Lift

8 Cleaning, Inspection,

1-39 1-40

Valve

Timing

Valve Clearance Manifold Vacuum Test

Reconditioning
Intake Manifold Exhaust Manifold
and

1-30 1-30

Oil Pan

and

Oil Pump

9 Repair Operations (Engine In Chassis) Engine Supports

1-40 1-40
1-41

1-13

Engine Compression Test 1-13

5 Engine Removal
and

Exhaust Gas Control

Valve
1-30

Intake Manifold Cylinder Heads

Installation 6 Engine

1-14

Valve Rocker Arm Shaft

1-42

Disassembly and Assembly (Engine Removed

from Chassis)
1-16

Assembly
Push Rods

...

1-30
1-30

Cylinder Front Cover

and

Timing
and

Chain

1-42
1-42

Cylinder Heads
Valves

1-30
1-32
1-34

Camshaft

Oil Pan

Oil

Pump

1-42

Disassembly
of

and

Assembly
1-27

Hydraulic Valve Lifters

Oil Filter
Exhaust System

1-43 1-43

Component Parts

Timing

Chain

1-34

DESCRIPTION

The Interceptor
engine and a

V-8
and

"Thunderbird
a

Special"

(Figs. I

2) has

4.00-inch bore

3.50-inch

stroke and a total piston cubic

dis

placement
pression

of 352

inches. It has
engine

a com

ratio a

of 10.2:1. The

is iden
the
also

tified
name

by

decal
"H"

on the air cleaner

bearing

of the engine.

It

can

be identified

by
1722-A

the

letter

at

the

beginning

of the serial

number on

the patent plate.

FIG.

1 Interceptor V-8 "Thunderbird

Special"

Engine

1-3

PLANT

1723-A

FIG. 2-Engine

Sectional View

1-4

GROUP 1-POWER PLANT

CLOSED (HEAT

ON)

OPEN (HEAT OFF)

1001
1541
-A

-A

FIG.

4 Exhaust Gas Control Valve

FIG.

3 Intake Manifold Exhaust Gas Passages

FIG.

6 Valve Port Arrangement

buretor (Fig. 5). The
the
and carburetor right
side

of

cylinders

feeds Nos. 1, 4, 6, and the left side feeds

Nos. 2, 3, 5, and 8 cylinders. The distributor is mounted at the left front of the intake manifold.
CYLINDER AND

HEADS

BLOCK
are
numbered

The cylinders front to rear on

from

3,
1312-A

and

and on

bank 1, 2, the left bank 5, 6, 7,

the right

and

FIG.

5 Intake Manifold Fuel Passages

When the
valve

8. The firing order is 1-5-4-2-63-7-8. The valves are arranged from front to rear on both banks E-I-E-I-IE-I-E (Fig. 6). The cylinder head assemblies con
The
combustion

MANIFOLDS

is

closed part

or
of

in the
the
ex

tain the valves and the valve rocker

arm shaft assembly.

"heat
The
serves

on"

intake
as

manifold,
valve

which

also

position,
gases
exhaust are

the

tappet
passage

haust
right

directed from

the

chambers are machined

chamber

Valve
the

guides

are

an

cover, the

contains

through

manifold, through the

exhaust

in the head. integral part of

center section and under

the car
exhaust vapor

heat

riser

passage, to the left

head. Both the intake

are

and exhaust valve

buretor,
gases are

through

which

hot

manifold.

When
more of

the

valve

opens

assemblies
which

the

rotating-type time

directed to

assist

in

"heat

off,"

the exhaust gases

rotate

each

the

valve of the

izing
into

the

incoming fuel
exhaust

charge

(Fig.

from the left

to flow

manifold are permitted

opens and closes.

valve stems

Lubrication

3). The
the

gases

are

directed
a

directly

out the exhaust sys

is

controlled
seals

by

umbrella-

intake

manifold

by

ther

tem in the normal manner.

type valve
sets

stem

which

mostatically

controlled

exhaust valve at

The intake
of

manifold

has two

the

top

of the valve stems.

fit over The valve

spacings

(Fig. A). The

outlet of

valve

is located

the

the right

exhaust

manifold.

separate

fuel passages, each with its inlet connection to the

own
car

springs which

have
provide

equal
more

coil

positive

valve

PART 1-ENGINE

1-5

VALVE OPEN
LIFTER BODY
VALVE CLOSED

PUSH ROD CUP

PLUNGER

PLUNGER SPRING DISC VALVE

DISC VALVE SPRING

BASE CIRCLE

1717-A

FIG.
action

7 Hydraulic Valve Lifter Operation Typical

at

high

engine

speed.

damper spring is installed inside the valve spring to assist in preventing

valve

bounce

and

floating
lifters
valve

at

high
used
and

rpm.

Hydraulic
which
minimizes operation

valve zero

are

into the plunger. This creates a differential above and below the valve disc. The high pressure above the valve disc forces the valve disc open and the oil fills the area below the plunger equalizing the
sure
pressure

pressure on

the oil below the plunger

and the valve

is
so

relieved

disc

opens

the chamber can again be

cycle

filled.

This

is

repeated at each revolu

tion of the camshaft.

The
oil

push rods are solid steel with

provide

lash

pressure

on

each

side

of

the valve

cushioned

sockets.

Inasmuch
the

as

valve

train

noise.

The
of

disc.
Whenever
clearance

there is no valve lash adjustment with

and parts

identification

between the

hydraulic
rocker

valve

lifters,
not

valve

the hydraulic valve lifters are shown

valve and the valve rocker arm tends

arms

do

have adjusting

in Fig. 7. When the valve is closed, lifter assembly is on the base circle of the camshaft lobe and the valve push rod is in its lowest posi tion. With the lifter assembly in this
the

to be present, the plunger spring ex pands pushing the plunger until there

screws.

is

solid contact

between

all parts of

the valve train mechanism.

As

the

camshaft valve

rotates

(valve

position, the plunger spring expands

opening) the
the sudden

forcing
tion
arm

the plunger upward. This ac

lifter is raised and increase in oil pressure

the lifter

is

transmitted to the valve rocker

below the disc

plunger

via

the
solid

valve

push

rod

until

closed and

forces the valve becomes a

this period a

The camshaft is supported by five insert-type bearings pressed into the block. It is driven by a sprocket and timing chain in mesh with a sprocket on the crankshaft. Camshaft end play is controlled by a thrust button and spring located between the camshaft sprocket bolt and the cylinder front
cover.

there

is

contact

between the
the valve

hydraulic
slight

ram.

During

valve and

the valve

end of

rocker arm

(zero

valve

lash). In

this

position, the oil hole in the lifter and plunger is indexed with the lifter oil

from below the plunger occurs. As the high point on the camshaft lobe rotates past the
leakage
of oil

An eccentric, bolted to the front end of the camshaft, operates the fuel pump.

lifter,

the push rod

forces

the valve

gallery

and oil

is forced

under pres

lifter down

and reseats

the valve. The

The crankshaft is supported by five insert-type main bearings. Crank shaft end thrust is controlled by the

1-6

GROUP 1-POWER PLANT

NO. 2 SUPPORT, LEFT HEAD NO. 4 SUPPORT, RIGHT HEAD

CYLINDER HEAD BOLT BORE

FROM NO. 2

CAMSHAFT BEARING TO LEFT CYLINDER

HEAD, AND FROM NO. 4

CAMSHAFT

BEARING TO RIGHT CYLINDER HEAD.

1514-A

1725-A

FIG.

8 Lubrication System

FIG.
bypass
the

9 Valve Rocker Arm Shaft Lubrication Passages

be
For example, the No. 1 oils No. 5 cylinder,

flanges of the No. 3 The forged steel,

main

bearing.
con

filter, if filter,

the element

cylinder wall.

"I"

section

comes clogged.

necting rods contain a bronze piston pin bushing. The connecting rod bearings are the insert-type.

From the
the
main oil

the oil
which

gallery

flows into is located

connecting etc. As the

rod

The aluminum alloy, three ring, flat head-type pistons are of the autothermic design. This design provides
controlled piston

expansion piston

which

allows

closer

initial

out

binding
and

or excessive

fits with friction. The

is
chrome-

top
ring

compression

plated

the

ring lower

compression

is
oil of

phosphate-coated

for

extra

protection against wear and scuffing.

The
sists

control a

ring assembly
spring
rails.
and

con

serrated

two

in the center of the valve chamber floor. The oil gallery supplies oil to each individual camshaft bearing, through drilled passages in the block. Passages are drilled from each cam shaft bearing to each main bearing. Number 1 camshaft bearing feeds No. 1 main bearing, and No. 2 cam shaft bearing feeds No. 2 main bear ing, etc. The oil then flows through notches or grooves in the main bear ings to lubricate the crankshaft jour nals. A metering plug at the front of
the
main

crankshaft turns, the hole in the connecting rod bearing aligns with the hole in the journal causing

direct
Oil

squirt of oil onto

the cylinder

wall. passages
oil
are

drilled from the

gallery to each valve lifter oil gallery. Oil from here feeds the
main valve at

lifter

assemblies.

reservoir

each
so

valve

lifter bore boss traps

oil

that oil

is

available

for

valve

lifter lubrication
starts.

as soon as the engine

An 2

oil passage

is drilled from No.

web

camshaft

bearing

to the left
and

chrome-plated

steel

oil

gallery

allows

any
oil

air

cylinder

head between Nos. 5

that

may be trapped
crankshaft

in

the

to

cylinders to arm shaft

lubricate the
cylinder

valve rocker
oil

LUBRICATION
Oil from the in the front
system of

SYSTEM
oil pan sump,

escape.

assembly (Fig. 9). The

located

The

is drilled from

the

passage

in the

the oil pan,

is forced
oil

through the pressure-type

lubrication

main bearings to the connecting rod bearings. The oil flow is as follows:

from
the

the cylinder

head is drilled head bolt bore to

(Fig.

8) by
pump,

rotor-type

Main

pump.

The

oil

mounted

in the

front of the crankcase, is driven by the distributor through an interme

Bearing
No. 1

Rod

Connecting Bearing
and and and

No. 2 valve rocker arm shaft support. The oil flows through the
valve
rocker

arm

shaft valve

through
rocker
and

diate drive
relief

shaft.

spring

loaded

valve

in
the

the

pump limits the

the system.

maximum pressure of relieved

Oil

by

valve

is directed back

No. 2 No. 3 No. 4 No. 5

A
small

Serves Serves
Serves

No. 1
Nos. 2 Nos. 3 Nos. 4 No. 8
5 6 7

drilled
arm

holes in each to lubricate the

ends
of

bushing

Serves Serves
groove

both The

the valve rocker arm.

spirals and

excess
push

oil

tating

rods

down the ro lubricates the

push rod seats.

The

right valve rocker

to the intake side of the pump.

by the pump passes through a full flow-type filter before it enters the engine. The filter
All the
oil

discharged

connecting
where

rod

at

is located in the the mating face is

used as an oil

arm shaft
cated via

assembly is similarly lubri from No. 4 camshaft bearing

the cap contacts the connect

the

ing

rod.

This

groove

support.

No. 4 valve rocker arm shaft A baffle located under the

arm

is

mounted

in in

vertical

position

at

squirt

hole for Oil from

hole

cylinder wall

lubrica

valve
shields

rocker

shaft

the lower left front of the engine. A

relief valve

tion.
squirt

the

filter

permits oil

to

connecting rod lubricates the opposite

the

the

valve oil

stems

assembly from oil

to the

splash.

Excess

is

returned

PART 1-ENGINE

1-7

TO RADIATOR SUPPLY TANK

1515-A

1770-A

FIG.
cated

10 Crankcase Ventilation System

drain back holes lo
end of

FIG.

11 Cooling System
water

oil pan through

at each

the

cylinder

head and in the tappet chamber floor. The timing chain and sprockets are splash lubricated by a jiggle pin in the main gallery front plug.

CRANKCASE VENTILATION
A
crankcase ventilation

tube is lo

cated at

the rear of the engine. The

motion of

forward
partial

the car causes a

few contaminating vapors. Here, the incoming air has a chance to warm up before contacting contaminating vapors originating in the crankcase. Warm ventilating air minimizes the formation of crankcase sludge. The ventilating air is directed by a baffle, located on the underside of the intake manifold, upward into the front of both valve rocker arm cham bers. The baffle also directs air to the front of the lower crankcase and into
the

pump

which

delivers the

cool

ant to the cylinder

block (Fig. 11).

cored of

The
each

coolant

travels through

passages to cool the entire

cylinder

length

wall.

Upon reaching

the

rear

of

the cylinder

block,

the

coolant
cylinder

is directed upward into the heads where it cools the

chambers,

combustion

valves,
to the

and

valve seats on
of the engine.

its

return

front

vacuum

to be formed at the

timing

chain chamber.

The
sages

coolant

from

each

cylinder pas

tube. This

vacuum action causes air

to be drawn through the engine from

Air from the valve rocker arm from the crankcase chamber and flows into the
rod chamber. out rear of

head flows through the

water

in the intake
radiator

manifold and past

the oil filler cap located at the front of the intake manifold (Fig. 10). The

the valve push

the water

All

air

is then directed

into the
the

thermostat, if it is open, supply tank. If the

filler cap contains a filtering element which filters the incoming air. From the filler cap, the air flows into the front section of the valve
push

the crankcase ventilation tube.

thermostat
of

COOLING SYSTEM
The coolant is drawn from the lower tank of the radiator by the

water

entire
psi

is closed, a small portion is returned to the for recirculation. The pump system is pressurized to 13-15
coolant a

rod

chamber

where

there are

by

pressure-type radiator

cap.

GENERAL ENGINE TROUBLE SHOOTING

Poor
caused gine

engine

performance

can

be
of

misses;

rough

engine

idle;
not

poor

ac

rections

to be

made a

in the

various

by

the need of a general en

celeration;

engine
or

does
poor

develop
speed con or

systems.
can not

When

particular
a

trouble
system sys

tune-up,
parts,
good

by
or

gradual

wear

full power,
sumption;
engine

has

high

be traced to
could

definite fault

engine

by

sudden

parts

performance;

excessive

fuel

by

simple

check, the possible

failure. A
gine

trouble diagnosis will

of a complete en

engine

overheats;

the

tems that

be

at

are

listed

indicate the

need

tune-up, individual adjustments,

fails to reach tion temperature.

normal opera

in the

order of

their probable occur

rence; therefore, in most cases, the

trouble
shoot

part(s) replacement or overhaul, or the need of a complete engine over

Table 1 is

a general

checks should

be

made

in the

order

ing

chart

which

lists basic

engine

listed. Some consideration, however,

should

haul.
Engine
performance

troubles with procedures and checks

complaints

be

to be performed to
cause of

help isolate
after

the

example,
moved

usually fall under one of the follow ing basic headings: engine will not
crank;
engine

the trouble in a particular

given to logical order. For if the spark plugs are re for testing and they are not

system.
check

The
refers

reference

each

the cause of the

checks

cranks

normally, but

to

that

part

of

the

later

calls

trouble, and several for a compression

check

will not

start; engine starts, running;

engine

but fails but

manual

which

covers,

in

detail,

test,
sion

to save
while

time,
the

the compres
are

to

keep

runs,

checking

procedures as well as cor

spark

plugs

out.

1-8

GROUP 1-POWER PLANT

are

Separate trouble shooting charts included in the ignition, fuel,

cooling system sections of the These charts list the basic troubles listed in Table 1, but cover only the items relating to the particu
manual.

and

under consideration. For example, in Table 1 under Poor Ac celeration, the ignition system is listed system

lar

the ignition

acceleration should all

items that affect listed. These items be checked before proceed

system

are

as a probable cause of

the trouble. In

ing

to the next

probable system

listed

Ignition System Trouble Shooting Chart under Poor Acceleration, all

the

in Table 1.

I ADLt 1 General Engine Trouble Shooting

The in
the

cause of this

trouble is usually

starting

system

(Group

ENGINE WILL NOT CRANK

Part 2). If the starting

check
seized

for

system is not at fault, hydrostatic lock or a engine. Remove the spark

a
en-

the starter. If the engine it indicates that water is leaking into the cylinders. Remove the cylinder head(s) and inspect the gasket(s) and/or head(s) for cracks. Also examine the cylinder block for
gine
with

cranks,

plugs, then attempt to crank the

cracks.

Check the fuel

If
there

supply.

starter

is

sufficient

fuel in the
proba-

end
inch

ENGINE CRANKS

tank, the cause of the trouble bly lies in either the ignition fuel system.
_

/ from

cranking the engine, hold the the [od approximately 3/16

the cyhnder

blockor a weak

or the

If tnere
the

is

n0

sPark

spark, the cause of the trouble is in

NORMALLY, BUT
WILL NOT START

To

ignition
Tf the
plugs

system

isolate the cause:

(Group
good 1 Part

1 Part

2)

spark

is

check

the

ignition wire from one spark plug, and insert a piece of proper sized metal rod in the insulator so that it protrudes from the insulator. With the ignition on and the
Remove
the

spark

(Group

2). If
check

the spark plugs are not at the

fault,

fuel

system

(Group
is

1 Part

3). If
check

the

fuel

system

not at

fault,

the valve

timing (Group

1 Part

1).

ENGINE
BUT

STARTS,
If the
engine starts and runs
check

FAILS TO
RUNNING

for

Fuel

system

few seconds, then stops,

the:

Ignition

system

(Group 1 Part 3). (Group 1 Part 2).

KEEP

First, determine if
occurs

the miss

is steady
at

Ignition
Engine
which
engine

system

(Group
to

1 Part

2)

or erratic and at what speed the miss

compression

determine

by operating

the

engine

mechanical component of the

various speeds under

...

load.
T

is

at

fault (page 1-13).

.

Misses steady
..

at all speeds. r
m1_

Isolate
.4.
.

the miss
one
,

the engine with by operating r 7 j cylinder not firing. This done

r,
.

Misses erratically at all speeds. If parthe miss cannot be isolated in a r

..

...

-,,

is

ticular cylinder, '

-

check

..

the:
valve

by operating
tion
wire
at a
u
.
.

iU

.,

Exhaust
.

gas

control

11/

the engine with the

igni~ft,

(page r
.

removed
m.t

from
,. .u

one
.

spark

ENGINE

RUNS,

BUT MISSES

plug u been
wire

time,
1

until all cylinders

r*

have
plug

Ignition
J?
-

checked.
removed

\ Ground the

spark

11

(Group 1 Part 2). ' / % Fuel system J (Group 1 Part 3).

system
.
_.
_^

.,

,~

t>

-^

Engine
engine

...

compression

to

determine

which mechanical component of the

If the
a

engine speed changes when

is

at

fault (page 1-13).

for
excessive

particular

cylinder was

is

shorted

out,

Exhaust
pressure.

system

back

that

cylinder

delivering
If

power

before in the
not

being

shorted out.

no change

Cooling
and/or

system

for internal leaks

that prevents
normal

engine

operation

is evident,

for

a condition

the miss was caused

by

that cylinder

the

engine

from

reaching

delivering
out,

power

before

being

shorted

check

the:

operating Part 4).

temperature

(Group

PART 1-ENGINE

1-9

TABLE 1

General

Engine Trouble

Shooting (cont'd)

ENGINE RUNS, BUT MISSES

(cont'd)

Check the: Fuel system (Group 1Part 3). Ignition system (Group 1 Part 2). Vacuum booster pump, lines and fittings for leaks. Engine compression foT low com pression (page 1-13).
Misses
at

idle

only.

Misses
the:

at

high

speed only.

Check

Ignition Fuel

system

(Group

1 Part

2).

system

(Group

1-Part 3).

for overheating or Cooling internal leakage (Group 1Part 4).

system

Check the: Fuel system

ROUGH ENGINE IDLE

(Group 1Part 3). Ignition system (Group 1Part 2).

Exhaust
gas control valve

Power brake leaks (Group 6

vacuum

booster for

Part 2).

(page
and

Engine

supports

for looseness

1-30)
Vacuum booster pump, lines fittings for leaks.

(Group (Group

1-Part 1).
cylinder

Improper

head bolt torque

1-Part 1).

Check the:

POOR

Ignition system (Group 1 Part 2). Fuel system (Group 1 Part 3). Exhaust gas control valve (page
1-30).

Clutch for slippageConventional Drive and Overdrive Transmission (Group 2-Part 1). Cruise-O-Matic
transmission

ACCELERATION

Brakes for (Group 6).

proper

adjustment

proper

adjustment

(Group 3

for Part

2).

Determine
when

if

the

trouble

exists

All
the:

engine

temperatures.

Check
1-13).

is cold, operating temperature, or

the engine
gine

at normal

at all en

Engine Ignition

compression
system

(page

temperatures.
cold. gas

Engine

Check the:
control valve

Fuel
(page

system

2). (Group 1 Part 3). (Group

1 Part

ENGINE

DOES NOT

Exhaust
1-30).

Camshaft lobe lift (page 1-11).

Valve timing (page 1-12).

DEVELOP FULL POWER,

Fuel

system

(Group
if

1 Part

3).

OR HAS POOR HIGH SPEED PERFORMANCE

Cooling

system

engine

reaches

operating temperature slowly 1-Part 4).

(Group

heats

Cooling system if the engine (Group 1 Part 4).

Exhaust
system

over

for

excessive

back

Engine

at normal

operating tempera
valve

pressure.

ture. Check the:

Exhaust
1-30).

gas

control

(page

Torque 3). Brake

converter

(Group

3 Part

adjustment

Fuel

system

(Group

1 Part

3).

Tire

pressure

(Group 6). (Group A Part

3).

Determine
sumption
stalled

the

actual

fuel

con

with

test

equipment

in

consumption

If the test indicates that the fuel is excessive, make a

in the

car.

EXCESSIVE

FUEL

If the test indicates that the fuel

consumption strate

preliminary check of the following items before proceeding to the fuel

and

CONSUMPTION

is

not

excessive, demon

ignition

systems.
checks

to

the

owner will

how improper

driving

habits

affect

fuel

con

Preliminary
Tires

sumption.

(Group

Part 3).

1-10

GROUP 1-POWER PLANT

I ABLE 1 General

Engine Trouble

Shooting (cont'd)

Wheel

alignment

(Group

4 Part

EXCESSIVE FUEL CONSUMPTION (cont'd)

1). Brakes (Group 6).

Exhaust
1-30).
gas control

(Group 1 Part (Group 1 Part Part Ignition system (Group 1

Ignition timing
system

2).

Fuel

3). 2).

valve

(page
8

Engine
Torque 6).

compression

(page 1-13).

Cooling
calibration

system

Odometer Part 1).

(Group

converter

(Group 1 Part 4). (Group 3 Part

Temperature sending 8-Part 1).

^

unit

(Group
8-

Cylinder head bolt torque (Group 1-Part 1).

,_

ENGINE OVERHEATS

Temperature

gauge

(Group
valve

Cooling
\r

system

(Group

1 Part

4).

Part X)Exhaust
1-30).
gas

i t 7it\ Valves (page 1-32).

control

(page

Exhaust Brakes

system.

(Group 6).

ENGINE FAILS TO REACH

NORMAL OPERATING TEMPERATURE

Temperature sending 8-Part 1). Temperature Part 1 )

.

unit

(Group
8

Engine

thermostat

(Group

Part 4).

gauge

(Group

TUNE-UP
A tune-up is
them
within

systematic

procedure

for testing

various

engine

components, and,

if

necessary,

bringing

recommended specifications to restore

engine

efficiency

and performance.

The

Tune-Up Schedule

(Table

2)

is

applicable

for

either a minor or major

recommended each

tune-up. A

minor

tune-up is

recommended each

6000

miles and a major

tune-up is

12,000

miles.

The
to

reference after each operation refers

to that part of the manual which

sequence

describes, in detail,

the procedure

be followed. Perform

the operations

in the

listed.

TABLE

2 Tune-Up Schedule
Perform
Operation Minor
Major
on

Recom
mended

Perform

on

Recom
mended

Operation
Minor
BATTERY Clean battery
terminals.

Procedure

Major

Procedure

SPARK PLUGS

Group 1
X X
Part 2

cables and

Clean,

adjust, and test.

X X X

Tighten ENGINE COMPRESSION

cable clamps.

Group 7
Part 1

Grease battery terminals.

X Page 1-13

Take

compression

reading

Check
charge.

of each cylinder.

battery

state of

INTAKE MANIFOLD

Group 1
X X
Part 1

ELECTRICAL Check generator Check

output.

Group
Part 1

Check

and tighten

bolts.

starter motor

current

draw.

X
X
circuit

DRIVE BELTS

Group 1
the ten

Check

coil output.
a

Check

and

adjust

Part 4 X X

Perform

Group
Part 2
X

sion of all

drive belts.

primary

resistance test.

PART 1-ENGINE

1-11

TABLE 2-Tune-Up Schedule (cont'd)

Perform
on

Recom
mended

Perform

on

Recom
mended

Operation
Minor

Operation
Minor Major

Major

Procedure
FUEL SYSTEM

Procedure

ELECTRICAL

(Confd)
X

Group 1
Part 2

Perform a secondary circuit

continuity test.

Clean fuel pump filter bowl.

Replace fuel pump filter bowl strainer. Check fuel pump
pressure

Group 1
Part 3

DISTRIBUTOR Check the condition breaker points.

Replace the breaker
and the condenser. of

the

and capacity.

X
points

Clean carburetor fuel bowls and adjust float setting.

ADJUSTMENTS

Group 1
ignition

Check
arm

and adjust

breaker
X

Check Check

and adjust

Part 2 X

spring tension.

timing.
and

X
X

Lubricate the distributor cam. Oil the lubricating wick. Lubricate the dis
tributor

adjust

engine

idle

speed. mixture.

X
X

Group 1
Part 3

Group
Part 2 X

Adjust idle fuel VACUUM

X
Page 1-13

bushing

through

the oil cup.

Check

manifold vacuum.

Check dwell. Check

and

adjust

point

X
and adjust centrif

EXHAUST

Free the
trol
ugal advance.

Group 1
Part 1

exhaust gas con

valve.

COOLING SYSTEM
Inspect the radiator, hoses, and engine for leaks.

Check

and adjust vacuum

advance.

X
and

Group 1
Part 4

Clean distributor cap

rotor.

Add
X
X

rust

inhibitor

to

radiator.

TESTS AND ADJUSTMENTS

(ENGINE IN
CAMSHAFT LOBE LIFT
Remove the valve rocker arm shaft assembly install a solid tappet-type push rod in the

CHASSIS)

and

push rod sure

bore

the push rod

then install a
to

Make is in the lifter push rod cup, dial indicator in such a manner as
of

the valve to be checked.

have the actuating

point of the

indicator in
the

the push rod socket and

the push rod movement
crankshaft
until the

in the

same plane as

(Fig. 12). Rotate

slowly in the direction

of rotation

BE SURE TO PLACE Indicator TIP IN CENTER OF PUSH ROD SOCKET

shaft

lifter is on the base circle of the cam lobe. At this point, the push rod will be in its lowest position. Set the dial indicator on
until the push rod

zero, then continue to rotate the damper slowly is in the fully raised position.

Compare the total lift

with specifications. 1748-A shaft until

recorded on the
rotate

indicator

Continue to the indicator reads

the crank

zero.
of

This later

FIG.

12-Camshaft

Lobe Lift

step is a indicator

check on the

accuracy

the original

reading.

1-12

GROUP 1-POWER PLANT

TABLE

3 Valve Timing Specifications

Intake Valve

Opens

Closes

Crankshaft Degrees

Camshaft Lobe Lift

Crankshaft Degrees

Camshaft Lobe Lift

21

B.T.C.

0.017

51

A.BC.

0.019

Exhaust Valve

Opens

Closes

Crankshaft Degrees

Camshaft Lobe Lift

Crankshaft Degrees

Camshaft Lobe Lift

1719-A

67B.B.C.

0.017

A.T.C

0.019

FIG.

13 Valve Clearance

VALVE TIMING
The
when noted

tor and continue

should

turning

the crank
of rota

stem and

the rocker arm of the valve

valve
poor

timing
all

be

shaft

checked

slowly in the direction

being
gauge

checked.

If the first step

will not

of

the

engine

performance

is
as

tion until the

the

specified

dial indicator registers camshaft lobe lift (Table

crankshaft

enters, the old push rod may

be

used.

and

other

checks,

such

If the first step

the

enter,

carburetion, ignition timing, etc. fail to locate the cause of the trouble.

3).

replace

standard push rod with a

timing is checked, check for a bent timing pointer. Bring the No. 1 piston to T.D.C. on
Before the
valve

Compare the indicated on the

degrees

shorter service ond

push rod. gauge

If the
enters,

sec

quadrant with speci

step

of

the

the

fications (Table 3). After the valve opening is checked, continue to ro

tate
the

operating

the compression stroke and see if the

damper to

check

the valve

lifter is exces sive which indicates that the incorrect push rod has been installed or severe
range of the wear

timing T.D.C.

pointer
mark

is

aligned

with

the

closing.

has

occurred

at
or

the push rod

valve

on

the

damper.

ends, rocker arm,

stem.

In

If the

valve

specifications, check the

camshaft

timing is not within timing chain,

crankshaft crankshaft and

VALVE CLEARANCE
A 0.060 inch
available means
of shorter

push

rod

is
a

this case, it will be necessary to de termine the area of discrepancy and

sprocket,
camshaft,

for

service

to

provide

sprocket,

in

the order of accessibility.

sional changes
with the

compensating for dimen in the valve mechan

stem

To

check the valve

timing
as
on

ism. Valve
ance
with

incorrect or defective part(s) be replaced. Before the clear ance is checked position the crank shaft as outlined in step 2 and 3.
the
should

to rocker arm clear

engine

installed,
a

proceed

follows:
crank

should

be

0.062-0.1875

inch
1

2. Rotate the
piston

crankshaft until
at

No.

Install
shaft

quadrant

the the

damper.

Remove

right and

hydraulic lifter completely collapsed. Repeated valve recondi

the

is

on

T.D.C.

the end of

the compression stroke. With

piston on

No. 1

valve rocker arm shaft

remove

assembly

tioning
valve

operations seat

(valve
will

and/or

T.D.C,

check

the follow

the

No. 1 intake

valve push

refacing)

decrease if
not
valve

ing

valves:

install a solid tappet-type push rod in its place. Make sure the push rod is in
rod

(the

second push

rod) and

this clearance to the point that

compensated

No. 1 Intake
No. 3 Intake No. 7 Intake No. 8 Intake
3. After these

No. 1 Exhaust
No. 4 Exhaust

for,

the

hydraulic

lifter

would

cease

to

function. To
the

the
a

lifter

push

rod

cup, then

install

determine

whether a shorter push rod

make

No. 5 Exhaust
No. 8 Exhaust
valves

dial indicator in

such a manner as

is

necessary,

following
com
and

have the actuating point of the indicator in the push rod socket and
to

check:

1. Position the hydraulic lifter

pressor

have been
piston on

checked,

position and

No.

in

the

same

plane

as

the

push

rod

tool

on

the

rocker

arm

T.D.C.
valves:

check

the

movement

( Fig. 12). Turn

until

the

crank

shaft

damper slowly in the direction

the

slowly apply pressure to bleed down the hydraulic lifter until the plunger

following

of

rotation

lifter is

on

the

lobe. At this point the push rod will be in its lowest position. Zero the dial indica
base
circle

of the camshaft

is completely bottomed (Fig. 13). Hold the lifter in the fully collapsed and insert the clearance position gauge (Fig. 13) between the valve

No. 2 Intake
No. 4 Intake No. 5 Intake No. 6 Intake

No. 2 Exhaust No. 3 Exhaust No. 6 Exhaust No. 7 Exhaust

PART 1-ENGINE

1-13

to remove

When compressing the valve spring push rods, be sure the pis ton in the individual cylinder is be low T.D.C. to avoid contact between
the
valve and

TABLE 4 Manifold
Gauge
19-20 inches.

Vacuum Gauge Readings

Reading
Normal.

Engine Condition

the

piston or serious

damage could To replace

result.
a push

rod, it will be

necessary to
er arm shaft

remove the valve rock

assembly as outlined on page 1-16, step 2. Upon replacement of a valve push

rod

Low

and steady.

in all cylinders caused possibly ignition or valve timing, or loss of compression due to leakage around the piston Loss
of power

by late
rings.

and/or

valve

rocker

aim

shaft

assembly, the engine

should

cranked or rotated until the

not be hydraulic

Very low.

Manifold,
leak.
A

carburetor, or

cylinder

head

gasket

lifters have had an opportunity to leak down to their normal operating position. The leak down rate can be
accelerated

partial or complete

loss

of power
a

in

one

in

by using the tool shown Fig. 13 on the valve rocker arm

pressure

as speed

Needle fluctuates steadily increases.

or more cylinders caused

by

leaking

valve,

cylinder
a

applying
collapse

in

direction to

head or intake manifold gasket leak, defect in the ignition system, or a weak

the

lifter.
Gradual
at engine

valve spring.

MANIFOLD VACUUM TEST

A
manifold
vacuum

drop in
idle.

reading

Excessive back
tem.

pressure

in the

exhaust sys

test aids in
to locate the

determining
cause of

the condition of an en

gine and also

in

helping
engine

An

occasional

loss

of power

possibly

caused

poor

performance.

Intermittent fluctuation.

To test manifold vacuum: 1. Operate the engine for a mini mum of Vi-hour at 1200 rpm. 2. Install an accurate, sensitive vacuum gauge on the fuel pump end of the fuel pump vacuum line. 3. Operate the engine at recom mended idle rpm. 4. Check the vacuum reading on
the
gauge.

by a defect in ing valve.

Improper idle
retor or

the ignition system or a stick

Slow fluctuation
of

or

drifting

mixture

adjustment,
gasket

carbu or pos

the needle.

intake manifold sibly late valve timing.

leak,

ENGINE COMPRESSION TEST

1. Be sure the battery is good. Operate the engine for a minimum of Vi hour at 1200 rpm. Turn the ignition switch off, then remove all
the spark plugs.

above normal
posits

indicates

excessive

de

in the

cylinder.

TEST CONCLUSIONS

A reading of more than 20 pounds below normal indicates leakage at

the cylinder
or valves.

Manifold
carburetor

vacuum

is

affected

by

head gasket,

piston

rings,

adjustment, valve timing,

and

the condition of the valves, cylinder

A low
adjacent

even

compression

in two
a

compression,
manifold,

leakage
or

of

the

carburetor,

cylinder

2. Set the primary throttle plates and the choke plate in the wide open
position.

cylinders

head gaskets. Because abnormal gauge readings may indicate that more than one of the above factors is at fault, exercise caution in analyzing an abnormal reading. For example, if the vacuum

inder head gasket should be checked before condemning the

rings or valves.

indicates leak. This

cyl

3. Install a compression No. 1 cylinder.

gauge

in

To determine
the
the
valves

whether at

the rings or
squirt

4. Crank
gauge
and

the
a

engine

until

are

fault,

the

registers

maximum
reading.

is low, the correction of one item may increase the vacuum enough so as to indicate that the trouble has been corrected. It is important, there

record of

the

reading Note the

re

equivalent of a oil

tablespoon of

heavy

in the

combustion

chamber, then

number

compression

strokes

quired to obtain the maximum read

ing. 5. Repeat the test

on each

fore,

that each cause of an abnormal

cylinder,

reading be investigated
tests conducted
order

where

further necessary in
and

cranking the engine the same number of strokes for each cylinder as was
required to obtain a maximum read

distribute the oil and repeat the compression test. The oil will temporarily seal leakage past the rings. If approximately the same reading is obtained, the rings are sat isfactory, but the valves are leaking. If the compression has increased 10
crank

the engine to

to arrive at the correct

diag

pounds

nosis of the

trouble.
various

ing

on

No. 1

or

more

over

the

cylinder.

original
past

reading,
rings.

there

is

leakage

the

possible causes. This table is merely a guide, however, and not a firm standard. Allowance should be made for the affect of altitude on the gauge read

Table 4 lists ings and their

types of read
TEST CONCLUSIONS

variation of pressure

specified

20 is

pounds

from

satisfactory.

However,
inders
pounds.

the compression of all cyl

should

be

uniform within

10

ing. The
with an

engine vacuum will

decrease

increase in

altitude.

A reading

of more

than 20 pounds

test, if the steadily and remains the same during the first two successive strokes, but climbs higher on the succeeding strokes, or fails to climb during the entire test, it indi cates a sticking or stuck valve.
a compression

During

pressure

fails to

climb

1-14

GROUP 1-POWER PLANT

1727-A

FIG.

14 Engine Installation

FIG.

15 Engine Lifting Brackets

and

Sling

ENGINE REMOVAL AND INSTALLATION

The
engine

procedures

given

are

for the

On

cars

with

Cruise-O-Matic dis

bracket). Remove the

crankcase ven

only without the transmission attached. If the engine and transmis

connect

the accelerator rod and the

rod at

tilation tube. Disconnect the muffler

transmission
cross shaft

the

accelerator

inlet

pipes

from the

exhaust

mani

sion are removed as an assembly,

stall

in

bracket
panel.
with

and secure them

folds,
port

the engine right and

at

left sup

standard

eye

bolts

with

Vi-IA
rear

to the

dash
cars

insulators
cars

the engine.

threads
of

in

the

bosses

at the

top

On

power

steering, dis

On
move

with

Cruise-O-Matic,

re

the

exhaust engine

manifolds.

Then

at
and

connect

the

power

steering

pump

the

converter

housing lower
to
converter

tach

the

lifting bracket
bolts. The

bracket from the

wire the power

water

pump, then

access cover and the cover assembly.

sling

to the eye

engine

in

stallation

is

shown

in Fig. 14.

steering pump to the hood left hinge in a position that will

prevent the oil

Remove
nuts.

the

flywheel

Secure

the converter

assembly
converter

from

REMOVAL
On
the
cars with

draining

out.

in the housing. Remove the

power

1. Drain the cooling system and crankcase. Disconnect the bat

ground cable at the engine.

brakes, dis
the

housing
remove

to engine

connect

the power brake line at the

and
at

the oil cooler

lower bolts, and lines retaining

block.
or overdrive

intake

manifold release

flexible

clamp from the On

units,

engine

tery

Re
air

move

the

hood,

line,

then

the

line from the

line.
conditioner,

conventional
remove

drive

radiator, and the

brackets

on

the left valve rocker arm

the

flywheel

housing
the

cleaner.

cover and remove the

oil

inspection
retracting
clutch

cover and the clutch pedal

spring.

2. Remove the
and the coil.
sure

level

dip

stick

Disconnect the
unit wire at

On

Disconnect
at

cars

with

an

air

oil pres

release

disconnect the
the sending
at

bracket

the equal

magnetic clutch wire.

sending

unit, the flexible fuel line

tank
wiper

the fuel

Isolate the
the

compressor as outlined

in

izer
the

rod and remove engine.

the bracket

from

line,
line

the
at

flexible

"1958

Air

Conditioner

Remove
engine

the

windshield

Shop
at

flywheel

Manual."

housing

to

upper

bolts.

the vacuum
of

position

it

out

the

way.

pump Remove
the

and

3. Disconnect the heater hose

the
water

transmission.
or

5. Lower the car, then support the Remove the converter flywheel

the wire loom

from the

clips on

pump

and

at

the

intake

left

valve rocker arm cover and posi

manifold, the generator wires at the

housing

upper

bolts.

Install the
on

engine

tion the wires out of the way.

generator, washer,
at

and

the

engine

tempera

retaining left lifting

mounts,

bracket

the front of the left cyl

where

On

cars with a windshield

ture sending
unit.

unit wire at

the sending

inder head
and

the

coil

disconnect
washer

the

three

lines

the

Remove the

engine ground

pump

and

position

them out

and the starter cable

strap retaining bracket

install
at

the

engine

right

lifting
engine
en

bracket

the rear of the right cyl

attach

of

the

way.
conventional

from the
drive
the

rear

of

the right cylinder

On drive
ator.

head.
or over
acceler

inder head, then

the

lifting
of the car.

sling (Fig. 15). Raise the

and

units,

disconnect

4. Raise the front

move

Re

gine

Remove the

accelerator retract

the starter and dust seal (and

carefully pull it from the transmission. Lift the en

slightly
engine

ing

spring.

the

Cruise-O-Matic

fluid filler tube

gine out of the

compartment

PART 1-ENGINE

1-15

tainer securing the

exhaust

gas

con

trol valve, then connect both

manifolds

exhaust

to the

muffler

inlet

pipes

and

tighten the

nuts

to 23-28 foot

pounds

torque. Position the dust seal

starter

and

install the

(and the

auto

matic

transmission

fluid

filler tube

bracket).
Remove the
mission and
support

from the trans

car.

lower the

7. Connect the

generator

wires, the
unit

engine temperature

sending

wire,
the

and

connect

the heater hose

at

intake

manifold.

Connect the install the

engine starter

ground
cable

strap

and

retaining clamp to the the right cylinder head.

rear of

8. Connect the flexible fuel line,

the oil
1728-A
pressure

sending
wiper

unit

wire,

and

the

windshield

vacuum

line.

FIG. 16-Engine
and

Work Stand

Install the primary

stall

coil

and

connect

the coil

and oil

high tension

wires.

In

the
wire

level dipstick. Position

clips

install it

on a work stand

(Fig.

gear) until the shaft

splines mesh with

the
on

loom in the retaining

rocker

16).

the

clutch

disc

splines.

the left valve

arm

cover.

3. Install the

crankcase ventilation

On

cars with a windshield

washer,

INSTALLATION
1. Position the
valve,
on
exhaust gas control

tube and the flywheel

verter

housing

or con
connect

the three

washer

pump lines.
con

housing
the
torque.

upper

bolts,
45-50

then

with a new gasket on each

side,

tighten
pounds

bolts

to

foot

On

cars with

Cruise-O-Matic,

nect the accelerator rod and

the trans

the

right exhaust manifold studs.

Temporarily
manifold.

tie

the
a

valve

to

the
over

4. Start the
support

engine

right

and

left

mission rod.

Place
the

new

gasket

insulator
the

to

engine

bolts.

On

conventional

drive

and

over

the

studs of

left

exhaust manifold.

Disconnect the
and
remove

engine

Loosen the
port

engine right and at

left sup
Attach sling

lifting
of

lifting sling brackets.

the car. In
or con

drive units, install the

accelerator re

tracting
tor rod.

spring.

Connect

the accelera

insulators
engine

the

chassis.

the

lifting
then

brackets

5. Raise the front

stall

and

the

flywheel

(Fig.

15),

remove

the

engine
verter

housing

On
nect

cars with power steering, con

power

from the

work stand. and

engine

housing

tighten

lower retaining bolts them to 45-50 foot

the

steering pump bracket

to the water pump.

2. Lower the
the
the

engine compartment. exhaust

manifolds

carefully into Make sure

are

pounds

torque.

On
On
move verter

cars with

power

brakes,

con

cars

with

Cruise-O-Matic

re

properly
pipes

nect

the power

brake line to the in

aligned

with

the

muffler

inlet

the retainer securing the con

take manifold and to the

and

flexible line

and the dowels

in the block

engage

the holes
converter

in the flywheel
housing.

housing

or

in the housing, then install the flywheel to converter lockwashers

and nuts.

install the line in the retaining clips on the left valve rocker arm
cover.

Tighten the

nuts

to 25-28
con

foot-pounds torque. Install the

On
the

cars with

converter

pilot

Cruise-O-Matic, start into the crank

verter

lower
cover

access

plate

and

the

On

cars

with

an

air

conditioner,

housing
On

assembly.

Install the

connect the magnetic clutch wire and

shaft.

oil cooler
conventional

lines retaining

clamp. or overdrive

the compressor

lines.
radiator.

On
units,

drive

or overdrive

start gear

the

transmission
clutch

conventional

main

drive

9. Install

the

Fill

and

drive

into the

disc. It may
position of

units, install the

nect

clutch

bracket. Con
Install

be necessary to
the

adjust

the

the clutch release rod and install

clutch

bleed the cooling system. Connect the heater hose at the water pump. Fill
the crankcase with the proper grade
and

transmission

in

relation

to

the

the

retracting

spring.

engine

if the input
the

shaft will not enter engine

the flywheel

housing
all

lower

cover.

quantity
and

of

engine

oil.

Operate
for

the

clutch
after

disc. If the
shaft

"hangs

6. Tighten
port

the engine front sup

and nuts

the engine at
gaskets

fast idle
hose

and check all

up"

enters, turn the

insulator bolts

to 45-50
re

connections
cleaner.

crankshaft

slowly

(transmission

in

foot-pounds torque. Remove the

leaks. Install the

air

1-16

GROUP 1-POWER PLANT

roo/-T53l-300-A

ENGINE DISASSEMBLY AND ASSEMBLY

(ENGINE REMOVED FROM

Standard Eye-Bolt

CHASSIS)

Y\6- 1 8 THREAD

ENGINE

DISASSEMBLY

INTAKE MANIFOLD

1. Disconnect the

wires at the spark plugs and remove

the wires from the ignition harness brackets on the valve

rocker arm covers.

Remove the distributor cap

vacuum

assembly.

Disconnect

the

distributor

line

at the

distributor.

Remove the

carburetor

fuel inlet line,

fuel pump
and

the vacuum pump

lines,
water

then remove the

radiator

discard the

gasket.

Remove the

supply tank. Slide the clamp

water pump.

on

the

pump bypass hose toward the

Remove

the automatic choke

arm covers.

heat

tube.

Remove the

valve rocker

FIG. 17 Intake
2. Crank the engine until the No. is at T.D.C. at the end of the If the hydraulic lifters
removed with

Manifold Removal

or

Installation

can not

be

piston

compression stroke.
shaft

Rotate the

crank

damper
on

an additional

45

(indi

fingers, remove the lock ring (Fig. 18), and the push rod cup (Fig. 19), and remove the lifter
the
and plunger shown

bolts and inlet tube

oil

remove

the oil pump and

as an

assembly, and remove

the oil pump drive shaft. Discard the

pump

gasket.

cated

the

damper
at

by

the symbol

XX).

Starting
the

the

No. 4 cylinder,
rocker arm

assembly with the tool in Fig. 20. After the lifter is

CYLINDER

FRONT COVER

loosen

right

valve

removed,

keep

all

the parts together

parts.

shaft support

turns at a

bolts in sequence, two time. After the bolts are all

remove

so as not to

intermix the
AND

1. Remove the fuel pump and dis card the gasket. Disconnect the drive

loosened,
arm shaft plate.

the
and

valve

rocker

EXHAUST GAS

MANIFOLD
VALVE

EXHAUST

belt adjusting arm at the generator. Remove the generator support bolt
at

assembly
same
rocker

the oil baffle

CONTROL

the water pump and the

at

bracket
Remove drive
pul

Starting
the

at the

No. 5 cylinder,
on

Remove
and remove

the

exhaust and

manifold

bolt
the

the cylinder block.

follow

procedure arm

the

lower retaining bolts

the
the

tab washers
manifolds. gas

generator,

brackets,
water
an

and

left

valve

shaft
must

support

exhaust exhaust
right

belts. Remove the

pump,

bolts.

This

procedure

be fol
valve push

Remove
valve

control
mani

ley,

and

fan

as

assembly. power

lowed to
rods

avoid

damage to the
valve

from the

exhaust

2. On
remove
washers

cars

with

mechanism.

Remove the
the

fold.
CYLINDER HEADS
cylinder

steering,

the two cap screws and lock

in

sequence.

3.

Remove
and

distributor

hold
the

Remove the

down bolt
manifold

distributor.

clamp and Remove the

remove

then install the cylinder

10

intake
Install

head bolts, head holding

the
not

securing the power steering pulley to the crankshaft damper, then

remove

the

pulley.

retaining

bolts.

fixture (Fig.
head
move
off

21).

Lift
Do

cylinder

the block.
and

standard eye

bolts

with

""i

e-

1 8 threads
the

pry be

Remove the large cap screw and washer from the end of the crank
shaft. shaft

tween the head

and

the block. Re
cylinder

Install the

puller on

the crank
remove

in

the

left front

and right rear rocker

discard the

head

damper (Fig.

22)

and

arm cover screw

engine

holes

and attach

gasket.

the
AND ADAPTER

damper.
crankshaft same

lifting

sling (Fig.

17).

Raise
OIL FILTER

the

manifold and
engine. gaskets

from the
manifold

it carefully Remove the intake

remove and
seals.

3. If the
stepped

sleeve

is

not

down (the it

O.D.

on

both

Unscrew
adapter.

the

oil

Remove the
and
an

oil

filter from the filter adapter

sending Discard the

ends),

remove

as shown

in Fig. 23.

4. Lift the hydraulic from

them

valve and

lifters
place

assembly
unit as gasket.

oil

pressure

the

cylinder rack

block
that

If the crankshaft sleeve is stepped down (different O.D. on each end),

remove

assembly.

it

with

three-jawed puller

in

so

they may be
bore. The
valve

(Tool 7675-N).
AND

installed in their
internal

original

parts of each

hydraulic

OIL

PAN

OIL

PUMP
oil pan
oil

4. Remove
retaining
pan.

the

screws cover

fastening
block,
cover. cover

lifter assembly not intermix the

semblies
cleaned.

are matched sets.

parts.

Do
as

1. Remove the
screws

the

cylinder

front

to the

Keep
are

the to

and

remove

the

Dis

then remove the cylinder

front front

intact

until

they

be

card

the gasket.
oil

5. Discard the
pump attaching
gasket.

cylinder

2. Remove the

PART 1-ENGINE

1-17

Tool HL1

1731-A
Tool HL 1

FIG.

18 Lock Ring Removal

FIG.
PUSH RODS

19 Push Rod Cup Removal

RINGS

CUPS

VALVE LIFTERS

Tool-T58P-6085-A

Too/ HI/

VALVE UFTER RACK

1733-A

1524-A

FIG.

20 Hydraulic Valve Lifter Removal

FIG.

21 Cylinder Head Holding Fixture

Tool-T58P-6316-A

1551-B

Crankshaft Sleeve

Tool T56P-6362-A

1552-B

FIG.

22 Crankshaft Damper Removal

FIG.

23 Crankshaft Sleeve Removal

1-18

GROUP 1-POWER PLANT

I
Tool T52L-6261-CEE

ToolT54L-6250B

Detail 6-BEARING REMOVAL BEARING REPLACER Detail 8

56-A

FIG. 25 Camshaft Bearing

Replacement

FIG.

24 timing Chain
Installation

and

Sprockets Removal

or

SPROCKETS AND TIMING CHAIN

been
oil

removed,
cylinder
until

remove

the

cutter

Tool T-7600-E to Remove the 25).

remove

the

plug.

Remove the
slinger.

crankshaft

front

from the

bore,

then turn the

at

camshaft

bearings (Fig.

Remove the
and

camshaft

thrust

crankshaft

the piston is

the

button
screw,

the

tainer, and Slide both

chain

cap button spring re the fuel pump eccentric.

thrust
sprockets

spring, the sprocket

top

of

its

stroke and

carefully

remove

the cloth with the cuttings.

ENGINE
caps

ASSEMBLY bearings for

are available

2. Make
(main
marked and

sure

all

bearing

CAMSHAFT BEARINGS

and

the

timing
the

forward,

and

remove

so

are rod) connecting they can be installed in

Camshaft
0.015-inch
eters.

pre-finished to size

standard and

sprockets and

timing

chain as an as

their

original

locations.
crankshaft until

sembly (Fig. 24).

CAMSHAFT

3. Turn the

the

Carefully
gine.

remove

the camshaft

by

connecting rod being down. Remove the pal

removed
nuts

is
the

and

pulling it toward the front

of the en

hex head
rod

nuts

from the connecting

rod and pis of the

journal diam not inter changeable from one bore to another. The bearings must be installed in their respective bores.
undersize

The

bearings

are

Use

caution to avoid

damaging

bolts,

then pull the cap off the

1. Position the

new

bearing
it in

at

the

rod.

the journals and lobes.

FLYWHEEL

Push the connecting

bearing bore,
with

and

press

place

ton assembly out the

top

cyl

inder
conventional

with

the

handle
wall

end of a

ham

the oil
oil

1. On
mark

flywheels,

mer.

Avoid damage to the

cylinder
when

crankpin

Fig. 25. Align holes in the bearings with the holes in the cylinder block when

the tool shown in

the pressure plate cover so that

or

the

it

can

be
and

replaced

in

the same posi

the

piston and rod.

removing Remove the bear

rods

tion,
plate

and remove the clutch pressure

ing
and

inserts from the connecting

caps. main

disc.

bolts

2. Remove the flywheel retaining and remove the flywheel.

4. Remove the

bearing

caps. of

are installed. Be sure the front bearing is installed 0.005-0.020 inch below the front face of the cylinder block (Fig. 26). 2. Clean out the camshaft rear

the

bearings

camshaft

Carefully bearing

lift the

crankshaft so that are

not

out

CRANKSHAFT AND CONNECTING ROD ASSEMBLIES

the cylinder

block

the thrust

bearing bore plug recess thoroughly. Coat the flange of a new plug with
water
with

surfaces

damaged.
care

resistant

sealer

and

1. Remove any

ridge

and/or car

Handle the

crankshaft

with

to

the

flange

facing

bon deposits from the upper the cylinder bores. Move the
to the bottom of
a cloth

end of
piston

avoid possible

fracture
surfaces.
seal

or

damage to

the
rear

finished journal
rear

its

travel and place

oil

Remove the from the block

and

Drive the plug in until slightly below the casting

MAIN
OIL

install it in (Fig. 27). it is flush or

surface.

on the piston

head to
the

collect

and

bearing

BEARINGS,

REAR JOURNAL

cap,
side

remove

the

cuttings.

Remove

cylinder

the
the

cap to block
main and

seals.

Remove
the

ridge with a

ridge cutter.

Follow the
the

instructions

furnished Never

by

tool

block

bearing inserts from bearing caps.

BEARINGS

SEALS, AND CRANKSHAFT The crankshaft and related

parts

are shown

in Fig. 28.

1. Be
shaft
oil

sure that all

and are

bearings,
the
rear

crank

manufacturer.

cut

into the

ring
has

CAMSHAFT

journals,

journal Install
a

travel

area

in

excess of

\':vi inch

when

Drill
shaft

'/2-inch hole in the

cam

seal

grooves

clean.

removing

ridges.

After the

ridge

rear

bearing

bore plug

and use

new rear

journal

oil seal

in the block

PART 1-ENGINE

1-19

INSTALL FRONT BEARING 0.005-0.020-INCH BELOW FRONT FACE OF BLOCK

Tool-T58P-6266-A

1S45-A

FIG.

26 Camshaft Front Bearing Measurement

FIG.

27 Camshaft Rear Bearing Bore Plug

Installation

CYLINDER BLOCK JOURNAL SEAL MAIN BEARING INSERTS

DAMPER

FLYWHEEL AND RING GEAR

POWER STEERING

PUMP PULLEY

MAIN BEARING CAPS

WASHER
1537- A

FIG.

28 Crankshaft

and

Related Parts

1-20

GROUP 1-POWER PLANT

Too/-T58P-<570?-A

1360-A

FIG.

29 Seal

to Block Installation

(Fig. 29) and rear main bearing cap (Fig. 30). After installation, cut the
ends of

the seals flush.

1459-A

2. If the crankshaft main bearing journals have been ground to a defi

nite

FIG.
main

30 Seal

to Rear

Bearing Cap
end

Installation

undersize,

install
main

the

correct

undersize

bearings.

bearing

Place the upper serts in position in

bearing in
with

by
the

squirting cap

cap side seals for leaks few drops of oil into

the

play is less than the

mini

mum

limit, inspect

the thrust bear

the
slot

bore

the

tang fitting
not get
under

in the

provided.

Do

ing
the

parting lines between the bear and the cylinder block from
outside.

ing faces for

or

scratches,

burrs,

nicks,

dirt. If the thrust faces

or

are not

de
the

dirt

or other

foreign

material

Blow

compressed

air

fective
not

dirty, they probably

properly.

were

the inserts. In time the dirt may distort the bearing and cause bear

against

the seals
air

from the inside

appear
oil

of

aligned

Install

the

block. If

bubbles

in the
per

ing

failure.
main caps.
crankshaft

oil, it indicates possible

leakage. be

3. Install the lower inserts in the 4. into

the

bearing

The

above
on

test should

not

bearing lowing the recommended (step 6), then recheck the

thrust
and align

the faces fol

procedure end play.

bearing

formed
the

Carefully
place.

lower the
careful not

sufficient seals

newly installed seals until time has been allowed for

to
expand

PISTON

AND

CONNECTING ROD

Be

to damage

into

the

seal

INSTALLATION

bearing

surfaces.

grooves.

Be
the thrust

sure

to install the

pistons

in the
were

5. Check
main

the

clearance

of

each

6. Install
with

bearing cap
against

same cylinders

from
which

which

they

bearing following the procedure under "Main Bearing (page 1-37). If the bearing clearances
Replacement"

the bolts finger tight, then pry

crankshaft

removed, or to

they

were

fitted.

the

forward

the

thrust surface of the upper

half

of

the

are

Each connecting rod and bearing cap numbered from 1 to 4 in the bank
and

are satisfactory,
engine

apply

light

coat of

oil

to the journals and bear

bearing
shaft

(Fig.

31).
and

Hold the

crank

right

from 5 to 8 in the
at

bearing caps, except the thrust bearing cap (No. 3 bearing). Main bearing caps are num
ings,
bered 1 thru 5 starting at the front of the engine. The arrows on the cap should be pointed toward the front
of

then install all the

pry the thrust bearing cap to the rear (Fig. 32). This will align the thrust surfaces of both

forward

left
the

bank, beginning
engine.

the front of

The

numbers on

the

con

necting
on

rod and

bearing
a

halves

of the

bearing. Retain the for

crankshaft,
and

the same side

cylinder

cap must be when installed in connecting rod one block or

new

ward pressure on the

the

bore. If

tighten the cap bolts to 95-105 foot

pounds

is

ever

transposed from
to another,
and

the

engine.

Tighten the
95-105

bearing
side

torque (Fig. 33).

the
crankshaft

cylinder

bearings
to
corre

should

be fitted be
the

cap
seals

bolts

to

foot-pounds

7. Force
the
rear of

the connecting

toward
a

rod

should

numbered

torque.

Dip

the rear
engine

bearing cap
grooves.

the engine. Install

the contact
point

dial
rests

spond with

new cylinder number.

in light

oil, then immedi

indicator
against

so

1. Oil
oil.

the

piston

ately install them in the

not

Do

rings,

the crankshaft
axis

flange

pistons,
engine

and

the

and cylinder walls with

light

use

sealer

on

the side seals, the to

expand
sealer when

indicator
shaft

is

parallel

to the crank
on

seals

are

designed
oil.

axis

(Fig. 34). Set the dial

the

2. Make
properly

sure

the

dipped in

Using

may

re

zero,
ward

then push the crankshaft

and note

for
the

ring

gaps

are

spaced

around

the circum
a piston

tard this expansion. It may be neces for the sary to tap the seals into place last Vi inch of travel. Do not cut the
seal

reading

on

ference
ring
push

of

the piston.
on

Install
the
a

dial. If the
end

compressor

piston

and

play

exceeds

the wear

the

piston

in

with

hammer

projecting

ends.

Check the

rear

limit,

replace

the thrust

bearing. If

handle

until

it is slightly below the

PART 1-ENGINE

1-21

1 546-A

-M

1547-A

FIG.

31 Thrust Bearing
Forward

Alignment

Pry Crankshaft

FIG.

32 Thrust Bearing
Backward

Alignment

Pry Cap

?
m

A-

V- *
*

1505- A

FIG. 34-Crankshaft
1548-A

End

Play

FIG.

33 Thrust Bearing

Alignment Tighten

Cap

1-22

GROUP 1-POWER PLANT

Tool-6149-A

FRONT

/
ENTATIONS TO FRONT OF ENGINE
1566- A

1567-A

FIG.

35 Piston Installation

FIG.

36 Connecting Rod Side Clearance

BEARINGS

CAMSHAFT REAR

BEARING BORE

PLUG

TIMING CHAIN AND

CAMSHAFT SPROCKET

FUEL PUMP ECCENTRIC

BOLT AND WASHER

1 536-B

FIG.
top

37 Camshaft

and

Related Parts
TIMING MARKS
sure

of the cylinder

(Fig. 35). Be
rods

1539-B

to guide the connecting

to

avoid

damaging
Install the
tion in the

the

crankshaft
with

journals.

FIG.
the piston
all

38 Aligning Timing Marks

CAMSHAFT

piston

the indenta
the bottom of its stroke, then push

piston

head toward the

front of the engine. When installed, the bearing lock slots in the connect

the way down until the

The
shown
and

camshaft and related parts are

connecting
crankshaft

rod

bearing

seats on

the

ing
of

rod should
engine.

be toward the

outside

journal. Install the

con

the

3. Check

the

clearance

of

each

necting rod cap, then tighten the nuts to 45-50 foot-pounds torque. Install
the pal nuts and tighten them to 3-4

carefully the bearings.

in Fig. 37. Oil the camshaft slide it through the

TIMING CHAIN AND

SPROCKETS
position

bearing following under "Connecting

the

procedure

1. Place the keys in

slots on

in the

Rod

Bearing Re

foot-pounds torque. 5. After the

rod

the crankshaft and camshaft.

sprockets and tim

placement"

(page 1-38). If the bear

are
coat of engine oil

piston

and

connect

2. Position the

ing

clearances

to specifications,
to the

ing

assemblies

have
rods

been
on

in be

ing

chain on

the camshaft and crank

sure

apply

light
and

stalled, check the side clearance

shaft

(Fig. 24). Be

the

timing

journals

bearings.
crankshaft

tween the connecting

throw

each

marks on

the sprockets and chain are

4. Turn the

to

crankshaft

journal (Fig. 36).

positioned as shown

in Fig. 38.

PART 1-ENGINE

1-23

REFERENCE POINT

RIGHT SIDE OF CHAIN

FUEL PUMP ECCENTRIC

DOWEL

TAKE UP SLACK ON LEFT SIDE. ESTABLISH A REFERENCE POINT AND MEASURE DISTANCE A. TAKE UP SLACK ON RIGHT SIDE AND FORCE LEFT SIDE OUT WITH THE FINGERS AND MEASURE DISTANCE B. DEFLECTION IS A MINUS B. 1511-B

CRANKSHAFT FRONT OIL SLINGER

1 540-B
and

FIG.

39 Timing Chain Deflection

FIG.

40 Fuel Pump Eccentric

Installed

Front Oil Slinger

3. Rotate the
viewed

crankshaft

in

clockwise

direction (as

side of

from the front) to take up the slack on the left the chain. Establish a reference point on the block
from this
point to the chain

and measure

(Fig. 39). Rotate

the crankshaft in the opposite direction to take up the

Tool-T58P-6700-B
slack on of

the right side of the chain, then force the left side

the chain out with the fingers and measure the distance
reference point and the chain.

between the

The deflection
If the de

is the difference between the two

measurements.

flection

exceeds

Vi

inch,

replace

the

timing

chain and/or

sprockets.

4. Install the fuel pump

camshaft
retainer. pounds and

eccentric
and

(Fig. 40),

and

the

sprocket

cap

screw

thrust
screw

button spring
to 35-45 foot

Tighten the

sprocket

cap

torque. Install the camshaft thrust

button spring

thrust button. Install the crankshaft front oil slinger.

CYLINDER FRONT COVER AND FRONT OIL SEAL

Oil Seal Replacement. It is

1526-A
oil seal each

good practice to replace the

time the cylinder front cover is removed.

the old seal with a pin punch, then clean
cover. with

FIG. 41

1. Drive

out

Oil Seal Installation

out the recess

in the
new

2. Coat

seal

grease, then install the

until

seal

(Fig. 41). Drive the

recess.

seal

in

it is

fully

seated

in the

Check

the seal

after

installation
seal.

to be sure the

spring is properly

positioned

in the

1-24

GROUP 1-POWER PLANT

Tool-

T 521-6306- AEE

1553-B

FIG.

43 Crankshaft Sleeve Installation

the gasket contacts the then advance

adapter

face,

it Vi-turn.

OIL PUMP AND OIL PAN

1. Insert the

oil

pump drive Position

a

shaft new

into the
rool-T58P-6019-A

oil

pump.

gasket on the

1555-B
stall

pump

housing

and

in

the pump and shaft

as an assem

FIG.

42 Cylinder Front Cover Alignment

bly

(Fig. 46). Do

not attempt

to force
will not

the pump into position if it

seat readily.

The drive
with

shaft

hex may

Cylinder Front Cover Installation

crankshaft,

then

install the damper

(Fig. 44).
screw

be

misaligned

the

distributor

1. Clean the
and

cylinder

front

cover sur

on the crankshaft

shaft.

To align, into

rotate

the intermedi

the

cylinder

block

gasket

5. Install the damper cap

and

ate shaft

a new position.

Tighten
to

faces. Coat the block

and

gasket surface of

the

washer,

and

tighten

it to

130-

the

oil

pump

retaining

screws

cover

and

the cover bolt

145 foot-pounds torque.

23-28 foot-pounds torque.

power

threads with sealer.

gasket on

Position

new

On

cars

with

separate

2. Position

new

gasket

on

the

the block.
cylinder

steering pulley, install the pulley

on

oil pan and place

the oil pan assembly

2. Install the
alignment

front

the
cover

crankshaft

damper. Tighten the

on

the

block.
and

Install the retaining

them

screws pilot

tool on the cylinder the the

to 23-28 foot-pounds torque.

water

screws

tighten

from the

front

cover

so

keyway in

the

6. Clean the
surfaces and

pump

gasket

center outward to

12-15 foot-pounds

pilot aligns with

key

in the

crank
pilot

apply

sealer.

Position install

torque.

shaft. over

Position the

cover

and

new gaskets on

the pump

and

the end of the crankshaft and

the block (Fig. 42).
cylinder

the water pump, pulley, and

an
assembly.

fan

as

FLYWHEEL

against

Position the flywheel

power

on

the crank

3. Install the

front

On
cover
power

cars

with

steering, the
retained

shaft

and

install the retaining bolts.

the

bolts finger tight. Position the

erator erator support

gen

steering pump is

by

Tighten
pounds

bolts

to

75-85

foot

bracket
arm

the
and

water

the gen then

pump retaining bolts.

a new

torque.

adjusting

bracket,
on

in

7. fuel

Using
pump.

gasket, install the

the

On

cars with conventional

drive

or

stall

the bolts.

Install

generator,

overdrive

transmissions,
clutch

use

Tool
then

While

pushing

in

the

pilot,

brackets,

and

drive belts.

7563 to locate the

disc,

tighten the cover bolts to 12-15

pounds torque.

foot
OIL FILTER AND ADAPTER

install the

pressure plate.

Tighten the

Remove the

pilot.

retaining bolts to 23-28 foot-pounds

shown
adapter

4. Lubricate the
a white

crankshaft

with

The

oil

filter assembly is
oil

torque.

lead

and oil mixture and

oil seal

lu

in Fig. 45. Clean the

gasket new
surfaces.

filter

bricate the
with sleeve

rubbing
the

surface

Apply
and

sealer

to

CYLINDER HEAD
a

grease.

Install
with

crankshaft

adapter

gasket, and install the

gasket.

1. Clean ket

carbon

deposits from the

and gas

(Fig.

43)
is

the smallest O.D.

adapter

assembly

Clean

sealer residue and

cylinder

end

into the
sleeve

cylinder

front

cover

bore

the

adapter

filter

recess.

Coat the
oil, then
on

head
ply
a

block

gasket surfaces.

Ap

if

the

stepped

down (differ

gasket on a new place

filter

with

coating

of

head
new

gasket

sealer

ent

O.D.

on

each end).
with

Line up the

the

filter in

position

the
until

to both sides of a

head

gasket.
spread

damper

keyway

the

key

on

the

adapter.

Hand tighten the filter

Use the brush furnished to

PART 1-ENGINE

1-25

OIL PRESSURE
SENDING UNIT

ADAPTER

GASKET

Tool T52L-6306AEE

1SS4-B
FILTER ELEMENT

FIG.

44 Crankshaft Damper Installation

1528-A

FIG.

45 Oil Filter Assembly

haust
muffler

gas

control

valve

over

the

inlet

pipe studs of the mani

fold, using
of

a new gasket on each side

the

valve.

Temporarily
new

tie

the

valve

to the exhaust
a

manifold. gasket

Position
muffler

over

the
ex

inlet

pipe studs of the

left

haust

manifold.

2. Position the
on

exhaust

manifold

the cylinder

head

and

install the

retaining bolts and tab washers. Tighten the retaining bolts to 23-28 foot-pounds torque, working from the
center to

the ends. Lock the bolts

by

bending

one tab of the washer over

FIG.

46 Oil Pump

and

Inlet Tube Installed

flat

on

the bolt.

INTAKE MANIFOLD

the sealer evenly over the

entire gas

torque in the
tighten
pounds

same sequence.

Finally,
foot

ket

surface.

Guided

by

the

word

the

bolts

to

80-90

The intake
shown

manifold

assembly is

"front"

on

the gasket, install the

the cylinder
cylinder

head

torque in the same sequence.

cylinder

in Fig. 48.
outside
of

gasket over

head dowels.

After the

head bolts have

1. Coat the

each

hy
to
not
will

2. Place the
tures.

head

on

the

engine, then remove the

holding fix
with

been tightened to specifications, the bolts should not be disturbed.

EXHAUST MANIFOLDS

draulic
provide

valve

lifter

with engine oil

initial lubrication.
with oil.
after

Do

Coat the head bolt threads

fill the lifters fill

much

The lifters

water resistant

sealer, then install the

faster

the engine is
of

bolts.

1. Coat the mating

graphite grease.

surfaces of the

started, if

exhaust manifold with a cylinder

light film

they
may

are

free

any

oil

of

film

which

cause an oil seal

3. The

ing

procedure

is

performed

head bolt tighten in three

torque

be

On
using
matic

tween the
exhaust

plunger

the
a

right

manifold,
auto

progressive steps.

Tighten the bolts to

new

gasket
air

install the
the

Place
which

each

and lifter body. lifter in the bore from

60-70
proper

foot-pounds
sequence

in

the then

choke

it

was removed.

chamber
sure

cover
cover

on

(Fig.

47),

the

manifold.

Be

is

2. Clean the mating

the

surfaces

of

tighten

them

to

70-80 foot-pounds

securely fastened.

Position the

ex

intake manifold,

cylinder

heads,

1-26

GROUP 1-POWER PLANT

CRANKCASE BREATHER CAP

OIL FILLER TUBE

WATER

V><5

MANIFOLD-TO-BLOCK FRONT SEAL

TEMPERATURE

USE Too/-S-8683

SENDING 1532-A
UNIT

MANIFOLD-TO-HEAD

GASKET

FIG.

47 Cylinder Head Bolt Tightening Sequence

CRANKCASE
VENTILATION TUBE

CYLINDER HEAD GASKET TABS

INTAKE MANIFOLD LOCATING DOWEL VACUUM PUMP

CONNECTION

INTAKE MANIFOLD

MANIFOLD-TO-HEAD

GASKET

MANIFOLD-TO-BLOCK REAR SEAL

1519-B

FIG. 48-lntake

Manifold

Assembly

the

compression

stroke.

Rotate

the
45

crankshaft

damper
on the

an additional

(indicated

damper
the

by

the sym
valve

bol

XX).
arm

Install
shaft

right

rocker

assembly

and

the
with

baffle
POSITION NOTCH OVER RIDGE ON SEAL MANIFOLD GASKET TABS
1520-B

plate on the cylinder

head

the valve push rods

rocker shaft sure

in

place and the

support

bolts

finger

FIG.
and

49 Intake Manifold Gasket Installation

tight.

Be

the shaft is turned so

that the oil holes are to the

cylinder

bottom.

block. Coat the intake

cylinder
with

After the intake

run

manifold

is in place,
neoprene

Starting
the

at

the No. 4 cylinder, tighten

two turns at a

manifold
prene sealer. seal

and

block
oil

neo-

finger
to

around

the

bolts in sequence,
until

surfaces

resistant

seal

area

make sure

the seals are

time,

the supports

fully

contact

Position
and

new seals on new

the cyl
on

in

place.

If the

seals are not manifold

in place,
and re

the cylinder head.

Tighten

the

bolts

inder block
cylinder

gaskets

the

remove position

the intake the

seals.

in

sequence

to

45-50
at

foot-pounds
5
cylin

heads

with

the gasket rest

Start
on

the
the

torque.
water

Starting
valve

the No.

ing
Be

on the cylinder
sure

head

gasket tabs. gaskets are cylinder

pump

by-pass Be

hose
sure

intake

der, follow the

the
port

same

procedure
arm shaft

for sup

the

holes in the
the holes

manifold.

the
and

holes in the
manifold are

left

rocker

aligned with

in the

manifold

gaskets

bolts. The

additional

time con

heads. To
place

keep
the

the neoprene seals

in is

in

alignment.

Install the
and

sumed
manifold re

in

this procedure will permit

while

intake

manifold

taining
23-28

bolts

the
tighten them

to

hydraulic lifters to leak down.

will

being
with

positioned, tape
placed

secure

the

seals of

foot-pounds
center

This
torque,
ends.

minimize the

working

possibility

of

in

each

corner

from the

to the

Remove

bending

the push rods, valves, or the

the outside edge of the seal surface.

the distributor and the engine

rocker arms.

lifting
radia

Be

sure

that the hydrau

The
kets

correct and

installation is
shown

of

the

gas

sling

and eye

bolts. Install the

lic lifters have leaked down to their

normal

seals

in Fig. 49.

tor supply tank.

operating

position

before

cranking the engine. This is neces

3. Install the

eye

bolts in the in

4. Install the

valve

push

rods

in

sary in
age

order

to avoid possible dam

or valve

take manifold and attach the engine

their proper sequence,

the

making
rods

sure posi

to the valves, push rods,

lifting
intake

sling

and

carefully lower the

on

lower

ends of

the

are

rocker arms.

manifold

the engine (Fig.

manifold

tioned

in the lifter

push

rod cup.

6. Install

the

automatic

choke

17;. Position the intake

by
1

5. Crank the
piston

engine until the

at

No.

heat

tube.
until

Rotate
the No.

the

crankshaft
on

inserting

the

distributor

in

place.

is

on

T.D.C.

the end of

damper

1 piston is

PART 1-ENGINE

1-27

T.D.C,
1

then position the distributor

with

Connect

the

distributor

vacuum

cylinders

are on

properly
page

positioned.

in the block

the rotor at the No.

line. Install the distributor

nect

cap.

Con
the

See Fig. 9
vacuum

1-48. Install the

and

firing

position and the points open. clamp.

the

spark

plug

wires.

Be

sure

booster pump line

the

Install the hold down

spark

plug

wires

for No. 7

and

carburetor

fuel inlet line.

SPRING WASHER

ROCKER ARM

SUPPORT

BOLT

ROCKER SHAFT

COTTER PIN

1527-B

FIG.

50 Valve Rocker Arm Shaft Assembly

DISASSEMBLY AND ASSEMBLY OF COMPONENT PARTS

VALVE SHAFT
ROCKER

ARM

stall a of

plug, cup side out,

rocker

in

each end

ASSEMBLY

ASSEMBLY

the

arm

shaft.

1. Install
arms,

each

valve

(Fig.

52) in
a

DISASSEMBLY

3. Install the
cotter valve
pins rocker

rocker

sup

the port
or

from

which

it

was removed

1. Remove the
each

from
arm

ports,

and springs

in the
the

order shown oil

to which it was fitted.

Install

end

of

the

in Fig. 50. Be
the shaft are
plete

sure

holes in

new stem seal on

the valve.

shaft, then
and

remove washers.

the

flat

washers

facing

downward. Com

2. Install the

valve

spring

assem

spring

the assembly

by installing
washers with
and

the

bly

over

the valve, then install the

and sleeve.

2. Slide the

rocker

arms, springs,

remaining two flat

the

spring

retainer

and the supports off the shaft.

Be

sure

spring
stall

washer

between them

in
3. Compress the spring
and

the cotter pin.

install

to

identify

all parts.

the retainer locks (Fig. 51).

remove

3. If it is necessary to
plugs

the

CYLINDER
the

HEADS
of

4. Measure the
of the valve

assembled

height
surface

from

each

end

of

shaft,
DISASSEMBLY

spring from the

drill
steel

or pierce one

plug, then insert a

the cylinder head spring pad to

rod through the plug and knock

1. Clean the
cylinder

carbon

out

of

the

the underside of the spring retainer

with

out

the

plug

on

the

opposite

end.

head

combustion

chambers

dividers (Fig.

53).
against a scale.

Working from
out

the open end,

plug.

knock

before removing the 2. Compress

the

valves.

Check the dividers

If the
assembled
springs or

the remaining

height is 15%4 inches

valve

ASSEMBLY

(Fig.
all

51),

then remove the spring re

and
release

greater, install the necessary 0.030cyl

1. Oil
oil.

moving

parts with engine

tainer

locks,

the spring.

inch thick spacer(s) between the inder head spring

pad and

the valve

3. Remove the sleeve, spring

the
plugs were removed

re

spring to
to

bring

the assembled

height
of

2. If
the
or

from

tainer,
and
seals.

spring

assembly

stem
valve parts.

seal,
stem

the

recommended

dimension
not

ends of

the shaft, use a

blunt tool

valve.

Discard the
all valve

15%4-15%4

inches.

Do

install
of
spac-

large diameter

pin punch and

in

Identify

spacers unless necessary.

Use

1-28

GROUP 1-POWER PLANT

SLEEVE

Too/-65?3-EE
LOCKS

SERVICED AS
AN
ASSEMBLY

SPRING
RETAINER

OIL SEAL

DAMPER

SPRING

EXHAUST

VALVE

1525-

INTAKE VALVE

FIG.

51 Removing

1542-B
or

Installing

Valve

Spring

Retainer Locks

FIG. 52-Valve
position over of

Assembly
engine

ers
will

in

excess

of

recommendations

valve

in

the oil hole on

oil.

Position the connecting

piston and
push

result

in overstressing the
will

valve

the

bottom
valve

the plunger.
on

Set the
disc.

rod

in the
place.

the

pin and

springs

which

lead to

excessive

disc

spring

top

of the

into

Assemble the
rod with

piston oil

load loss

and

spring breakage.

Position the disc

the disc and

valve retainer over

and
push

connecting

the

squirt

spring

the re

hole in the connecting

as

rod positioned

HYDRAULIC
Each
sembly.

VALVE
lifter is
a

LIFTERS
matched as

tainer

down into

place on the plunger.

shown

in Fig. 57.
new

valve

Place the
plunger

plunger
end

spring,

then

the

If the

parts of one

lifter

are

(open

up) into the lifter

2. Insert

piston

pin

retainers

inter-mixed improper

with

those

of

another,
result.

body. Place the

plunger.

push rod seat

in the

by
the the

spiraling

them

into the

piston with

valve operation

may

Position the lock ring in the in Fig. 18

on page

fingers. Do instructions

not use pliers.

Follow

contained on the pis

Disassemble
separately.

and assemble each

lifter

tool shown

1-17,
seated

Keep

the lifter
so

assemblies

then

install the lock ring in the lifter

sure

ton ring package and install the piston

rings.

in

proper

sequence

that

they

can

body. Be

the lock ring is

be installed in their
DISASSEMBLY

original

bore.

in the

groove.

3. Check the ring

of

side

clearance

the compression

rings with a

feeler
and

PISTON AND CONNECTING ROD

lock
with

gauge

inserted between the ring

Remove

the

ring

from

the

DISASSEMBLY

its lower land (Fig. 58). The

pistons and
pins

gauge

lifter assembly

the tool shown

Mark the
sure

to

should slide
as

freely
that

around the entire without

will

in Fig. 18
push
rod

on page
seat

1-17. Remove the

and
plunger

assembly

with the same rod and

ring

circumference
wear
at

binding.
form
a

plunger

installation

in

the

same

cylinder

Any
step

occurs

spring. and

Invert the
the

plunger

assembly
retainer

from
move
piston

which

they

were removed.
rings.

Re

the

inner

portion of

the lower

remove

disc

valve

the
pin

piston

Remove the
the

land. If the lower lands have high

steps, the
piston should

by

carefully prying up
then

on

it

with

retainers,

then drive

be

replaced.

screwdriver,
valve
and

remove

the

disc

pin out of the piston and rod

connecting
retainers.

4. Install the connecting

spring.

bearing inserts
cap
with

in the

(Fig. 55). Discard the

rod and

the tangs

ASSEMBLY

ASSEMBLY

fitting
get rod and re

in the

slots

provided.

Do

not

The hydraulic

valve

lifter

assem

dirt

or other

foreign

matter under

bly
a

is

shown

in Fig. 54.
plunger

The piston, connecting

the inserts. In time the dirt may dis

tort the

Place the
clean

upside

down

on

lated

parts are shown

in Fig. 56.
with

bearing

and

cause

bearing

work

bench. Place the disc

1. Lubricate

all

parts

light

failure.

PART 1-ENGINE

1-29

UNDERSIDE OF SPRING RETAINER

LOCK RING

DISC VALVE RETAINER

mm\^^\A^MMmM

PUSH ROD CUP

BODY

^
FIG.

DISC VALVE

r\ier

DISC VALVE SPRING

\j a i we

PLUNGER

SPRING
1716-A

54 Hydraulic Valve Lifter

Assembly Typical

OIL RING ASSEMBLY

SURFACE OF SPRING PAD

1 530-A

FIG.

53 Valve Spring Assembled Height

BOLT

CONNECTING ROD
COMPRESSION 'A'

UPPER

\$P
\
y^/

RING
'

PISTON

ToolT52P-6135-DAD

4Mf

RETAINER

BEARING INSERTS

1S59-A

FIG.

56 Piston, Connecting Rod,

and

Related Parts

1119-B

FIG.

55 Piston Pin Removal

LEFT BANK

RIGHT BANK

INDENTATION TO FRONT OF ENGINE

1120-A

mm.

1 564-B

FIG.

57 Connecting Rod

and

Piston

Assembly

FIG.

58 Ring Side Clearan ce

1-30

GROUP 1-POWER PLANT

OIL

PUMP

into

the oil pressure relief valve cham

and
pull

2. Install the

outer

race,

and

the

DISASSEMBLY

ber cap
the oil

the

cap

out of

the
and

inner
inner

rotor

and shaft

assembly.

The

1.

Remove
pump

inlet tube from

chamber. plunger.

Remove

the

spring

rotor and

shaft, and the

outer

the oil

and remove the gasket.

race are serviced as an assembly.

part should

One

2. Remove
screws,
move

the

cover

then remove

retaining the cover. Re

and shaft as

ASSEMBLY

not

be

replaced

without

replacing the The

oil

other.

Install the
cover

cover

pump assembly is

shown

and

tighten
to

the

the

inner

rotor

in Fig. 59.
1. Oil
the
oil all parts

screws

6-9

retaining foot-pounds torque.

the oil

sembly, then

remove
a

the outer

race.

thoroughly. Install plunger,

Position

a new gasket and

inlet

3. Insert
metal
screw

self

threading

sheet

pressure and
new

relief valve

tube on the oil pump

and

install the

of

the proper diameter

spring,

cap.

retaining bolts.

CLEANING, INSPECTION,
INTAKE
Clean

AND RECONDITIONING
through
90

MANIFOLD
the manifolds

freely
in
a

rotation

approximately without binding.

is
closed
when

of

The
checked

push

rods

can

be

visually

suitable

for

straightness

while

they

solvent, then
sed
air.

dry

them with compres

all

The
gine

valve

the en

are

installed in the
be

engine

Scrape

carbon

deposits

is

at normal

from

the center exhaust passage

riser.

be

ture and running ever,

open
a

at

operating tempera idle speed. How

them with the valve

can

by rotating closed. They also

dial indicator.

checked with a

low the carburetor heat

carbon acts as an

This

the

heating

insulator restricting action of the hot exhaust

for cracks,
that
would

properly operating valve will when very light finger pressure

to the counterweight. Ra the engine to make
accelerate

(Fig. 61). If the

maximum

runout exceeds the

limit

at

any point, discard

to straighten

is

applied

the

rod.

Do

not attempt

gases.

pidly
sure

push rods.

Inspect the

the
valve

valve

manifold

leaks,
make place

or

other

defects

The
the

momentarily opens. is designed to open when

CYLINDER

HEADS

it

unfit

for further
that
are

service.

Re
or

engine

is

at

normal

operating high

CLEANING AND INSPECTION

temperature
stripped
all

and

all

studs

is

operated at

Clean the
valve guide

valve guide

bores

with a

otherwise

damaged. foreign

Remove

fi

rpm.

Free

stuck valves with

a pene

cleaning tool. Use clean

to
remove

lings have

and

matter

that

may

trating
VALVE

oil and graphite mixture.

ing

solvent

old

gasket

entered

the manifold as

a result

sealer,

dirt,

and grease. cylinder

of repairs.

ROCKER

ARM

Check the

head for cracks,

Check

the

baffle

plate on the under

SHAFT ASSEMBLY
Clean
Make
all

and the gasket surface

for burrs

and

side of the manifold

for looseness.

nicks.

Replace the head if it is

crack

the

parts
all

thoroughly.
passages

ed.

Do

not plane or grind more

than

sure

that

oil

are

0.010 inch from the

gasket surface.

cylinder all

head
or

EXHAUST

MANIFOLD AND

open.

Remove

burrs

EXHAUST GAS VALVE

Clean
heat

CONTROL

Check the

clearance

between
bore

each

scratches with an oil stone.

rocker arm and

the shaft

by checking
and

out the automatic choke air

the I.D. of the rocker arm

CYLINDER HEAD

FLATNESS
of

chamber

of

the

right

exhaust

the O.D. of the shaft. If the clearance

Check the flatness

head
gasket surface

the cylinder

manifold
air

(Fig.
and

60).

Make
holes

sure
are

the

between

any

rocker

arm

and

the

(Fig. 62). Specifi

are

inlet

shaft exceeds com

outlet

the wear

limit,

replace

cations

for flatness
overall,

0.006 inch

pletely

open.

Blow

out the automatic with compressed

the shaft and/or the rocker arm.

spect

In

maximum

or

0.003 inch in

choke air
air.

heat tube

the

shaft

and

the rocker arm

any 6 inches.
VALVE SEAT RUNOUT

Check the thermostatic spring

of

bore for nicks, scratches, scores, or scuffs. Dress up minor surface de

fects
with a

the exhaust gas control valve to make

sure

hone.
pad at

Check the
the valve end of
the

valve

seat

runout with

it is hooked
at

on

the stop

pin.

The

Inspect the
the

an accurate gauge

(Fig. 63). Follow

gauge
manu

spring stop is

the

top
of

of

the valve

rocker arms

for

a grooved radius.

instructions

of the

housing

when

the

valve

installed. The

action

is properly the valve is

If the
rocker

pad
arm.

is grooved, Do

replace

the

facturer. The

total runout should not

not attempt

to true

exceed the wear

limit.

illustrated in Fig. 4.

this surface

by

grinding.

VALVE

SEAT WIDTH
valve seat width
valve seat

To

check

the exhaust gas control

valve on

the car, make sure the spring

valve

PUSH

RODS
ends of

Measure the
64).

(Fig.
width

The
are

intake

holds the
gine

closed

when the en

Check the

the push

rods

limits

0.060-0.080 inch
seat
width

and the
are

is

cold.

Actuate

the

counter

for nicks, grooves, roughness,

cessive wear.

or ex

exhaust

valve

limits

weight

by

hand to

make sure

it

moves

0.070-0.090 inch.

PART 1-ENGINE

1-31

AIR INLET

DISTRIBUTOR INTERMEDIATE DRIVE SHAFT

GASKET

INLET TUBE
ASSEMBLY

Q*

1 509-A

FIG.

60 Automatic Choke Heat Chamber

PLATE

1531

-A

FIG.

59 Oil Pump Assembly

Ho/ding

fixture'

PUSH ROD
1003-A

(T) (3)
(2)

CHECK DIAGONALLY CHECK ACROSS CENTER

1729- A

FIG.

61 Push Rod Runout

FIG.

62 Cylinder Head Flatness

Runout Gauge

/
Seof Width Scale
'^^mmMmmtmr

J
S

O
a

'

'

1735-A

FIG. 63-Valve Seat

Runout

FIG. 64-Valve

Seat Width

1-32

GROUP 1-POWER PLANT

TO REMOVE STOCK FROM

BOTTOM OF EXHAUST

TO REMOVE STOCK FROM TOP OF

INTAKE

SEAT, USE SEAT, USE

OR
60

15

WHEEL

SEAT, USE

30

WHEEL

TO REMOVE STOCK FROM TOP OF

EXHAUST
5 60

WHEEL

1738-A

FIG.

66 Valve Seat Refacing

1/32"

MINIMUM

MAXIMUM VALVE

.REFER

FACE RUNOUT 0.002

TO SPECIFICATIONS FOR CORRECT DIAMETER

S
CHECK FOR BENT STEM

DO NOT REMOVE MORE THAN 0.010 INCH

FIG.

65 Reaming Valve Guides

45

EXHAUST

30

INTAKE

1739-A

FIG.
REAMING VALVE GUIDES
ream a

67 Critical Valve Tolerances

the

up pits,
valve

grooves,
runout.

or

to

correct

blue is
of

transferred to the

bottom

edge

valve guide

If it becomes necessary to (Fig. 65) to install

seat

After the

seat

is

the valve

face,
to

raise the valve seat.

a valve

ground, measure the seat width (Fig.

After refacing the

good valve practice with a

valve

seat,

it is
the

with an oversize stem, a

reaming kit
follow

64). Narrow the seat, if necessary to

lightly lap
grade

in

is

available which contains the

reamer and pilot

bring

it

within

limits.
remove enough

medium

lapping
com after

ing

combinations; a

If the
stock

valve seat width exceeds the

compound.
pound

Remove
valve

all

the

0.003-inch O.S. reamer with a stand ard diameter pilot, a 0.015-inch O.S.
reamer with

maximum

limits, from the top

from the

and seat

edge and/or

bot
the

the

lapping

operation.

and

0.003-inch O.S. pilot, 0.030-inch reamer with a

a
pilot.

tom edge of the

seat

to

reduce

width to specifications

(Fig. 66).
seat,
use
a

VALVES
CLEANING AND
INSPECTION
carbon

0.015-inch O.S.

On
30

the

exhaust

valve wheel

When going from

valve

standard

size

angle

grinding
the
seat)
and

to remove

Remove

all

and

varnish

to an

oversize

valve, always use

stock

from

bottom

of

the

seat

from the
or

valve with a

fine

wire

the

reamers

in

sequence.

Always
the

re

(raise the
wheel of

use a

60

angle

buffing

wheel.

The

critical

brush inspec

face the
guide

valve
reamed.

seat

after

valve

to remove stock from the

seat

top
15

tion points and tolerances of the valve

are

is

the

(lower the

seat).

illustrated in Fig. 67.

valve

On the intake
REFACING

valve seat, use a

Inspect the
of

VALVE

SEATS

angle

grinding

wheel

to

remove stock

the valve head

face and the edge for pits, grooves,

Refacing
be closely

of the valve seats should

coordinated

from the top

seat).

of

the

seat

(lower the

with
so

the

re

facing of the
centered.

valve

face

the

finished
and

The finished
tact
valve

valve seat should con center

of

seat will match

the valve

face

be

the

approximate

the
the

defects. Inspect the bent condition and the end of the stem for grooves or scores. Check the valve head for signs of
scores, or other
stem

for

valve

This is important so that the and seat will have a good com

face. To determine
the

where

burning
cracking.

or

erosion,

warpage,

and

valve seat contacts

pression tight

fit. Be

sure

that the re

seat with valve

face, coat Prussian blue, then set

Rotate the

the the

Defects,
that

such as minor

pits,

grooves, etc.
card

may be
are

removed.

facer grinding

wheels

are

properly
to a
valve

in

place.

valve with

valves

Dis severely dam

dressed.
Grind the
true
seat
45

light
exhaust

pressure.

If the blue is trans

the valve

aged.

valve seat

ferred to the
the
contact

center of

face,

Inspect the
ers,

valve springs and valve

valve

angle

and
30

the

intake

is

satisfactory.

If the blue

damper springs,

to a true

angle

(Fig. 66).
to clean

Remove only

enough

stock

is transferred to the top edge of the valve face, lower the valve seat. If the

locks,

and

sleeves

spring retain for defects.

Discard any defective

parts.

PART 1-ENGINE

1-33

Model TV-2 Runout Gauge

1015-A

740- A

FIG.

68Valve Face Runout

FIG.

69 Valve Stem Clearance

Valve

Spring

Tester

NOT MORE
THAN

1017-A

1019-B

FIG.
VALVE

70 Valve Spring Pressure

FACE RUNOUT
valve

FIG.
guide.
a

71 Valve Spring Squareness

VALVE SPRING PRESSURE

tacts the upper surface of the valve

Check the

68). The

wear

face runout (Fig. limit is 0.002 inch

Position

dial indicator
of

with

flat tip

against the center portion of

section
90

Check the valve spring assembly for proper pressure (Fig. 70). Weak
valve springs cause poor engine per

total indicator

reading.

the spherical

the tool at

approximately
VALVE STEM CLEARANCE

to the valve stem.

and

Move the tool back

to
valve

forth

formance; therefore, if
of

the pressure
the wear

on a

Check
guide
respective shown

the

valve

stem

plane
arm

that
action

any spring

approaches

parallels
and

normal

rocker

clearance

of each

valve

in its

limit,
VALVE

replace the spring.

take

the

indicator
SPRING SQUARENESS
each steel

valve guide

with

the tool

in Fig. 69 or its equivalent. Install the tool on the valve stem

until

fully

seated

and tighten

the set

screw, then permit the valve to drop away from its seat until the tool con

from the valve guide upper surface. Divide the indicator reading by 2 (division factor of the tool) to obtain the actual stem clearance. If the clearance ex
reading
without

lifting

the tool

Check

spring for squareness

square and a

using
plate square

surface
and

(Fig. 71). Stand the spring

on end on

the surface plate.

square.

ceeds the wear

limit, try

a new valve.

Slide

the

spring up to the

1-34

GROUP 1-POWER PLANT

OUT OF ROUND AND B VS D CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL

=

A VS B VS D A VS C

VERTICAL TAPER HORIZONTAL TAPER

LOBE

LIFT EQUALS

A MINUS B

1749-A

tmmwm*

1028-A

FIG.

72 Camshaft Lobe Lift Measurement

the

FIG.
and
seat

73 Crankshaft Journal Measurements

Revolve
serve of

the space

the

spring slowly and ob between the top coil spring and the square. If the
out of square more

valve

after

the

lapping

tom of the

body by

its

own weight. and

operation.

Assemble the lifter assembly

check

the

spring is

than

SELECT FITTING

VALVES
operation stem

assembly for freeness of by pressing down on the

Vi inch,

replace

it.
it
operation should

If the
clearance

valve

to valve
wear

guide

push rod cup.

exceeds

the

REFACING VALVES

limit,
valve over

is

recommended

that

the
next

ROCKER

ARM TO

VALVE CLEARANCE

The

valve

refacing

guide

be

reamed

for the

be closely
seat

coordinated with the valve

If the

valve and/or valve seat

will

have

size
with

valve

stem

(page
stem and

1-32). Valves

refacing
angle

operation
of

so

that

the
will

been refaced, it
check rocker with

oversize

diameters

of are

finished
match

the valve

face

the
arm

be necessary to clearance between the

and

0.003, 0.015,
available

0.030

inch

the valve seat. This

is impor
seat
will

pad

the valve stem

for

service.

Always

reface

tant so

that the valve

and

the

valve

train

the

valve seat when

the valve

guide

is

assembly

in

have

a good compression tight

fit. Be
wheels

stalled

in the

engine

(page 1-12).

reamed.

sure that the refacer are

grinding

TIMING HYDRAULIC
VALVE

CHAIN
all parts

properly dressed.
valve

LIFTERS
should

If the
sive

face
to

runout

is

exces and

Clean

in

solvent and

dry
the
or

and/or

remove

pits

The kept in
can

lifter

assemblies

be

them

with

compressed

air.

Inspect
and

grooves, reface the

a

exhaust valves

to

proper sequence so

that

they
lifter

the chain
sprockets

for broken links

and

true

45

angle.

Reface the intake

angle.

be installed in their Inspect

so
as

original po
each

valves

to

true

30

Remove

sition.

and not

test to

for cracks, damaged teeth. It is

that
all

worn

recommended

only
out

enough stock

to correct the run

separately

intermix the
part

the components be replaced

one

or

to

clean

up

the

pits

and

internal

parts.

If any
needs

of

the
re

if any

item

needs

replacement.

grooves.

If the

edge of

the valve
after

head

lifter assembly
place

replacing,

is less
replace

than

Vz2 inch
engine.

grinding,
will run

the entire lifter assembly.

CAMSHAFT AND BEARINGS

Clean the
camshaft

the valve as the valve

in

solvent and

too

hot in the
off

CLEANING AND INSPECTION

or score

wipe

dry. Inspect the

camshaft

lobes

Grind
marks

all

grooves

Thoroughly
clean

clean all
wipe

the parts them with

in
a

from the

end of

the valve stem,

solvent and

for pitting, scoring, normal wear. Lobe

istics may
result

and signs of ab
wear

character
gen

then

chamfer

as

necessary.

Do

not

clean, lint free cloth.

in pitting in the
not

remove

more

than 0.010

inch from

Inspect the
entire

parts

and

discard the if
any
part
gall

eral

area of

the nose portion of the

the

stem.

lifter
signs

assembly
of

lobe. This pitting is

to the
operation
of

detrimental
camshaft,

After refacing the valves, it is

practice

good

shows

pitting, scoring,
of

the

with

lightly lap in the valves medium grade lapping com

to
match

ing, or evidence Also, replace the

the plunger

non-rotation.

therefore, the
placed until

cam should not

be

re

entire

pound
remove

to

the seats.
compound

Be

sure

to

is

not

assembly if free in the body.

the

camshaft

lobe lift be

loss has
of

exceeded

0.005 inch. The lift lobes

should

all

the

from

the

The

plunger should

drop

to the bot

suspected

worn

PART 1-ENGINE

1-35

checked
of

by

measuring

over

the

top

the lobe with a micrometer and

subtracting the measurement of the base circle diameter (Fig. 72). Check the camshaft journal to

bearing
of

clearances
of

by

measuring the

diameter
ceeds

the journals and the I.D.

the bearings. If the clearance ex

the

wear

limit,
be
the

the camshaft

journals
size

should

ground

for

under

bearings
replaced.

or

camshaft

re

Too/-RC-500

placed, and/or the bearings

should

be

Bearings

are

available and
535-A

prefinished to size

for

standard

0.015-inch
ters.

undersize

journal diame
gear

Check the distributor drive for broken

nicks

or chipped

teeth.

FIG.
CONNECTING RODS

74 Cleaning Ring Grooves

Replace defective connecting bolts.
each

Remove light scuffs, scores, or from the camshaft machined

rod

surfaces with a smooth oilstone.

CRANKSHAFT
CLEANING AND INSPECTION

The connecting rods and related should be carefully inspected and checked for conformance to specifications. Various forms of en
parts
care

nuts and

Inspect
place

bearing carefully. Re
a

bearings that have

or worn of surface.

scored,

chipped,

Handle the
to
avoid age

crankshaft

with or

gine wear caused

by

these parts can

different
and

types

bearing
to

For the failures

Fig. 77. Fit
new

possible

fractures

dam

to the finished
crankshaft

surfaces.

Clean
then

be readily identified. A shiny surface on the

side
of

their causes

refer

pin

boss

Check the
appear

clearance of

bearings that

the

with

solvent,

the piston usually

indicates
or the

to

be

satisfactory.

blow

out all oil passages with com

air. main and

that a connecting rod

piston pin

is bent

bearings

where

necessary,

following

hole is

not

pressed

in

proper rela

the recommended procedure.

Inspect

connecting

rod

tion

to

the

piston

skirt

and

ring

After the connecting

sembled

rods are as

journals

for

grooves.

to
or

the piston, check them

cracks,

scratches,

grooves, or scores. Dress minor im

perfections with an oilstone.

Regrind

Abnormal connecting rod bearing wear can be caused by either a bent

for bend
ment

twist on a suitable

align

severely marred journals. Measure the diameter of

nal

connecting rod,
each

an
or

improperly
a

ma

jour

chined

crankpin,
rod

tapered con

fixture. Follow the instructions of the fixture manufacturer. If the bend and/or twist is excessive, the
connecting
rod should

in

at

least four

places

to deter
or under

necting

bore.
not
pat

be

straight

mine

out-of-round,

taper,
exceed

size condition

(Fig. 73).
the
wear

Twisted connecting rods will create an easily identifiable wear

ened or replaced.

If the journals

tern, but

badly

twisted

rods will

dis

PISTONS, PINS,
AND RINGS
CLEANING AND INSPECTION

limit, they
for the

should

be

reground

to size

turb the action of the entire piston, rings, and connecting rod assembly
and

next undersize

bearing.

may be the

cause of excessive oil

Remove
side of the

carbon

deposits from the

REFINISHING JOURNALS

consumption. give

piston surfaces and

from the

under
gum

Regrind the journal to

proper clearance with

the CLEANING AND INSPECTION

piston

head. Clean

the next under

will not

size

bearing. If the journal

up"

"clean
ance

to give the proper clear

maximum

with

the

undersize

Clean the connecting rod in sol including the connecting rod bore and the back of the inserts. Do
vent,
not use a caustic
all

from the piston skirt, pis ton pins, and rings with solvent. Do
or varnish not use a caustic a wire

cleaning

solution or

brush to

clean pistons.

Clean
groove

bearing
shaft.

available, replace the crank

cleaning

solution. com

the

ring

grooves with a

ring

Blow
reproduce

out

passages

with

cleaner

(Fig. 74). Make

sure the oil

Always

the same

jour

pressed air.

nal shoulder radius

nally.

that existed origi

radius will result

Too

small

signs

Inspect the connecting rods for of fractures and the bearing

out-of-round and taper.

ring slots (or holes) are clean. Carefully inspect the pistons for fractures at the ring lands, skirt, and
pin

in fatigue failure
Too large

of

the crankshaft.

bores for

If

bosses,

and

for scuffed, rough,

grooves

or

a radius will result

in bear
the

the bore exceeds the recommended

scored skirts.

If the lower inner

the piston.

por

ing

failure due to

radius ride of

limits

and/or

if the

rod

is

fractured,

tion of the

ring
with

bearing.

it
chamfer

should

be

replaced.

steps,

replace

After grinding,

the

oil

Check the
rod

have high The step

clearance.

piston pin to
clearance.

holes,

then polish the journal with a

grit

bushing
that

connecting Replace the is

so or reamed

will

interfere

ring

operation and

cause

excessive

ring

side

No. 320
gine oil. also as a

polishing
cloth

cloth and en

connecting
worn

rod

if the

bushing
be

Spongy,
of the

eroded areas near the edge

of

Crocus

may be

used

it
an

cannot

top

polishing

agent.

honed for

the piston are usually

or pre-ignition.

oversize pin.

caused

by detonation,

1-36

GROUP 1-POWER PLANT

I 1 74 1

-A

FIG.

75 Checking Piston Fit

surface on the thrust surface
center-

FIG.
low the
cylinder

76 Piston Ring Gap

before
to

A shiny
of

bore to
size

cool

If the

scale

reading is less than the

pull, recheck cal

the piston, offset from the

the piston fit is checked.

minimum allowable

line between the piston pin holes, can be caused by a bent connecting rod. Replace pistons that show signs of
excessive

Calculate
used

the

piston

be

culations

by taking
81),

a cylinder

bore

check

ton.

before trying another pis If none can be fitted, refinish the

for the
a
next

(Fig.

then select the proper size

cylinder

size piston.

wear,

wavy

ring

lands,
from
bore
and

piston ance.

to provide

the desired clear

When
mark

piston

has been

fractures,
detonation
clearance ribbon

and/or

damage

fitted,

or pre-ignition.
piston to cylinder
a

Make bore
gauge are

sure the piston and cylinder clean

and

Check the
and

dry.

Attach

it for assembly in the to which it was fitted. If the taper ditions

cylinder

a and out-of-round con

with

tension
side

scale

tension

scale

to the end of a that

feeler
or

the

ring

clearance proce

ribbon

is free
ribbon of

of

dents

of the cylinder

bore

are within

following
dures.

the

recommended

burrs. The feeler

Vi-inch
wide
mended

should

be

limits,

new piston rings will give satis

and

the the

recom

factory

service

provided cylinder
new

the

piston
with

Replace
of

piston or

pins

showing
and/or

signs
wear.

thickness

for

existing

clearance

in the
a

bore is

fracture
rod

etching

condition.

in limits. If the
installed in
not

rings are

to be

Check the
and

piston pin

fit in the
that
are

piston

bushing.
all rings

Replace
and

scored,
end

chipped, or cracked.

Check the It is
new

gap

side

clearance.

good
rings

practice
when should piston
mileage.

to

always

install

Position the ribbon in the cylinder bore so that it extends the entire length of the piston at 90 from the piston pin location. Invert the piston and install it in the bore so that the end of the piston is about 1 Vi inches below the top
and of the cylinder

used cylinder

that

has

been refinished, inder wall

"glaze."

remove

the cyl

Select the
size piston to

proper

ring

set

for the

be for

used.

The

rings must

be

checked

proper

overhauling the
not

engine.

Rings
one of

block
to the

gap in the
proper side

cylinder

bore

and

for the

be transferred from
another

the piston pin

axis.

is

parallel

clearance
check

in the

piston grooves. proper

to

regardless

crankshaft

First,
as

each

Hold the
scale

piston and

slowly
with

pull

the
rib

ring for

gap

in

follows:
Position the ring in the cylinder which it is going to be used. Push the ring down into the cylinder

straight

line

the

FITTING

PISTONS
are available
sizes

Pistons
standard

for

service

in

noting the move the feeler

bon,

pull

required

to re

ribbon
within

and

oversizes

for

use

If the

pull

is

in

cylinders

that

have been

rebored. and

existing condition,
satisfactory.

(Fig. 75). limits for the the piston fit is

greater

bore in bore
not

area where normal

Pistons

of

0.020, 0.030, 0.040,

oversize are available

encountered.

ring wear is Use the head of a

ring
so

0.060-inch
service.

for

If the

scale

reading is

than

piston to position the

that the

the maximum allowable pull, recheck

piston

ring is

square with the cylinder wall.

The
should
(70

and

cylinder

block

calculations

to

be

sure

that the proper

check
a new

Use

caution
or

to avoid damage to the

be
when

at

room

temperature

size

piston a

F)

the piston fit is checked.

al

for

has been selected, damaged piston, then try

After any refinishing operation,

piston.

bore. Measure the gap between the ends of the ring with a feeler gauge (Fig. 76).
cylinder

ring

PART 1-ENGINE

1-37

SCRATCHES

DIRT IMBEDDED INTO BEARING MATERIAL

LACK OF OIL

SCRATCHED BY DIRT

IMPROPER SEATING

OVERLAY GONE FROM ENTIRE SURFACE TAPERED JOURNAL

RADIUS RIDE

CRATERS FATIGUE FAILURE

1030-A

RADIUS RIDE

FIG.

77 Bearing Failures
chipped,
replaced.

mended set.

If the gap is less than the recom lower limit, try another ring

or worn surface

should

be
are

diameter

of the

Typical
and

examples

of

bear

ing

is fitted to the
minimum

journal. If the bear minimum diame

clearance, interfer
an

ing failures
shown

their

causes

ter with
ence

FITTING PISTON PINS

fit should be a light fit at normal tempera (70 F). Standard piston pins ture are color coded green. Pins of 0.001inch oversize (color coded blue) and 0.002-inch oversize (color coded yel
The
piston pin

thumb press

in Fig. 77. Check the clear ance of bearings that appear to be satisfactory with Plastigage. Fit new bearings following the recommended
procedure.

may

result,
not

causing
a

early
that

failure. It is
journal

recommended

bearings be fitted to
which exceeds

crankshaft
maximum

the

out-of-round specifications.

When
with

re

BEARING REPLACEMENT

placing

standard

bearings
proper

new

low)

are

available.

If the
piloted

pin

hole in the
use an

piston must

The main bearing inserts are selec tive fit and do not require reaming to size upon installation. Do not file
or

bearings, it is try to obtain

with

good

practice

to first

the

clearance

two blue
not get

bearing
dirt
or

halves.
other

Do
dirt
cause

foreign
and

be reamed,

expansion-type,
reamer

lap bearing
the

caps or use shims

to

matter under

the inserts. In time the the

reamer.

Place the

in

obtain

proper

bearing

clearance.

may

distort

bearing following

a vise and revolve

the piston around

reamer

the

reamer.

Set the

to

the

size of the pin

reamer

bore,

then expand the

Selective fit bearings are available for service in standard sizes only. Standard bearings are divided into
two sizes and are
of red or

bearing failure.
pro

Main Bearings. The

cedure

is for the If the

engine

installed in
on a work

slightly and trial ream the pin bore. Take a light cut. Use a pilot
sleeve of

identified
paint.

by

daub

the chassis with the crankshaft not

removed.

blue

Red

marked

engine

is

the nearest size to maintain

alignment of

the bores.

bearings increase the clearance; blue marked bearings decrease the clear
ance.

stand, follow steps 2-5. In step 4, it is not necessary to support the crank
shaft

Check the hole size, using the new piston pin. If the bore is small, ex
the reamer slightly and make another cut. Repeat the procedure
pand until

Undersize bearings,

which are

because the

engine

will

be in
on

not selective

fit,

are available

for

use

verted.

Place the Plastigage

the

on

journals that have been

and are
a not

reground. wear

crankshaft of on gine

Normally, bearing journals

evenly

journal (Fig. 78) instead the bearing surface if the en

on a work stand. one

the proper fit is obtained. Check

out-of-round.

is

for fit in the respective rod bushing. If necessary, ream or hone the bushing to fit the pin.
the piston pin

However, if
to fit the

bearing

is

being

fitted
sure

1.

Replace
the

bearing

at a

time,

to an out-of-round

journal, be

leaving

other

bearings securely
main

Install the
and
each place. rod.

piston pin
a

in the

bearing

to the maximum

fastened. Remove the

piston

bearing

Install
of

new

retainer

at

end

the

pin

to hold

it in

PLACE PLASTIGAGE FULL WIDTH OF JOURNAL ABOUT V. INCH OFF CENTER

CHECK WIDTH OF PLASTIGAGE 0.002

Spiral the retainers into posi tion with the fingers. Do not use pliers. Make sure the retainers are properly seated in their groove.

CLEARANCE

MAIN ROD

AND CONNECTING BEARINGS

INSTALLING PLASTIGAGE
and caps

CLEANING AND INSPECTION

Clean the
thoroughly.
carefully.

bearing inserts

MEASURING PLASTIGAGE 1031 -A

Inspect each Bearings that have

bearing
a

FIG.

78~~

scored,

mstamn9 and Measuring Plastigage Engine On Work Stand

1-38

GROUP 1-POWER PLANT

PLACE Plastigage FULL WIDTH OF JOURNAL ABOUT Va INCH OFF CENTER CHECK WIDTH OF Plastigage

0.0015"

CLEARANCE

MEASURING Plastigage

INSTALLING Plastigage

1558-B

1049-B

FIG 79 Installing

and

Measuring

Plastigage

Engine in Chassis

FIG.

80 Flywheel Face Runout

cap to which new bearings are to be installed. Insert the upper bearing
removal

If the
specified

clearance

is less than
two red
of red

the

ance.

Check the
point

Plastigage
order

at

the

limits, try
a

bearing
and

narrowest maximum

in

to get the

tool (Tool

6331) in

the oil

halves

or

combination upon

clearance.

The difference is the

red

hole in the
crankshaft
rotation

crankshaft.

Rotate the
of engine

blue
the

depending
standard clearance
grind

the condition.
not

between the If the

specified

two readings

taper.

in the direction force

the

If the

bearings do
within

bring

clearance

is less
two
of

than

the

to

bearing

out of

the

desired

limits, try
a

bearing
red and

the

block. To install
place over of

limits,
the upper main

the crankshaft

journal,
been

halves

or

combination

2.

bear bear

then

install After
a

undersize

bearings. has

ing,

the plain end of the

4.

the

bearing

blue depending upon the condition. If the standard bearings do not bring
the
clearance grind
within

ing
side

the shaft on the

locking tang
Tool 6331,
opposite

checked and

found to be satisfactory,
coat of engine oil to the

the

desired

the block.

Using

apply

light
and cap.

limits,
then

the crankshaft

journal,
has

rotate

the crankshaft

in the

journal

bearings,

then install the

install

undersize

bearings.
clearance

direction

of engine rotation until the

bearing

seats

itself. Remove the tool.

Tighten the cap bolts to bearing 95-105 foot-pounds torque. 5.

After

the

bearing
a

been

checked and

Replace the cap bearing. Clean the crankshaft journal and bearings.

If the

rear

main

bearing

is

re

factory, apply
oil to the

found to be satis light coat of engine

and

placed, replace the lower oil seal (in the cap) and the side seals. The upper
oil seal placed

journal

bearings,

then

3.

Support the
will not

crankshaft

so

its

weight

compress

the Plasti

(in the
with

block)

can not

be

re

install the connecting rod cap. Tight en the nuts to 45-50 foot-pounds torque, then install the tighten 3-4 them to
torque.
pal

gage and provide an erroneous read

the crankshaft installed.

nuts, and

ing. Position bear

against

small

jack
which

so

it

will

foot-pounds

the

counterweight

ad

Connecting Rod Bearings.

1.
Install the
new

joining
on the

the

bearing
a

is

being

checked.

Place

piece

of

Plastigage Va inch

bearings in the
Pull the
con

3.
quire

Repeat the
new

procedure
rods

for the
that
re

of the
off

bearing surface bearing cap and

the full width

about

connecting
necting
of rod

rod and cap.

remaining connecting

assembly down
on

bearings.

firmly

on

center

(Fig. 79). Install the cap

the bolts to

the crankshaft journal. Place

a piece

and tighten
pounds

95-105 foot
turn the

Plastigage
Va

the

lower

bearing

CONVENTIONAL
INSPECTION

FLYWHEEL

torque.
while

Do

not

surface, the full width of the cap and

about

crankshaft

the Plastigage is in

inch

off center.

Install the
rod

Inspect heat

the
or

flywheel for cracks,

other

place.

Remove the cap, then using the

check

cap
nuts

and

tighten

the connecting

check,

defects

that
serv

Plastigage scale,
to

the width of

to 45-50 foot-pounds torque. Do

would make

it

unfit

for further

the Plastigage at the widest point

order

in

not

turn

the

crankshaft

while

the

ice. Machine the friction If it is necessary to

surface

of

get

the minimum clearance.

at

Plastigage is in

place.

the flywheel if it is scored or worn. then

Check the Plastigage

point

the

narrowest

2.

Remove

the

cap,

using

remove more

than

in

order

to get the

maximum

the Plastigage scale check the width

of

0.045 inch thickness, Inspect

of stock

from the

original

clearance.

The

difference

between

the Plastigage at the widest point

order

replace the

flywheel. for worn,

the two

readings

is the taper.

in

to get

the

minimum

clear

the

ring

gear

PART 1-ENGINE

1-39

Check
CENTERLINE OF
ENGINE'

all

machined

gasket

sur

faces for
scores.

burrs,

nicks, scratches, and

minor

[Al A-AT
RIGHT ANGLE

Remove

imperfections

with an oil stone.

Check the flatness

gasket surface specifi cylinder

TO CENTERLINE OF ENGINE

of the cylinder

block

following

the

procedure

and

cations recommended

for the

head (page 1-30).

B"

PARALLEL TO

Replace
that

all

expansion-type

plugs

CENTERLINE OF
ENGINE

show evidence of

leakage.

Inspect the

cylinder walls

for

scor

ing,

roughness, or other
cylinder

signs of wear.
out-of-

Check the
round and

bore for

taper. Measure the bore

with an accurate gauge

following
of
each

the

instructions
|A>r.--.,

of

the

manufacturer.

Measure the diameter

-JSmmL
4

cyl
and

inder bore bottom

of

at

the

top, middle,
placed at

I.

OUT-OF-ROUND
=

DIFFERENCE BETWEEN A AND B

with

the gauge

right

2. TAPER

DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF CYLINDER BORE AND THE A MEASUREMENT AT BOTTOM OF CYLINDER BORE 1039-A

angles and parallel

to the

centerlines

the engine (Fig. 81).

Rebore

cylinders

that are

deeply
limits.
minor
out-of-

FIG.
chipped,
are

81 Cylinder Bore Out-of-Round And Taper

If the teeth
gear.

scored

and/or

when

out-of-round wear

and/or taper exceed

the

If the

cylinder

walls

have
the

or cracked teeth. replace

CONVERTER DRIVE PLATE for checking the drive plate for cars with Cruise-O-Matic is covered in Group 3.
The
procedure
converter

surface

damaged,

the

ring

imperfections, but
possible

round and taper are within

With the flywheel installed on the crankshaft, check the flywheel face
runout.

limits, it

may be

to remove the imper

fections
and

by honing the cylinder wall installing new service piston rings

FLYWHEEL FACE RUNOUT

Install indicator
wheel wheel

dial indicator

so

that the

CYLINDER BLOCK

within

providing the piston clearance is limits. Use the finest grade of

stone

point

bears

against

the

face (Fig. 80). Turn the

making
sure

fly fly

honing
During
inder
the

for this

operation.

disassembly

of

the cyl
REFINISHING CYLINDER WALLS

that it

is full for
as

ward or rearward so end

that crankshaft

block for engine overhaul, closely inspect the wear pattern on all parts to help diagnose the cause
of wear.

Honing is

recommended
walls

for

re

play

will not

be indicated
exceeds

finishing
such as

cylinder

only

when

fly

the walls have minor

imperfections,

wheel

runout. runout

If the
mum

the

maxi

CLEANING AND INSPECTION

light scuffs, scratches, etc. The grade of hone to be used is deter

sol

limit,

remove

the flywheel and

Thoroughly
vent.

clean the old

block in

mined

check and

for burrs between the flywheel

mount

Remove

gasket

material

removed.

the face of the crankshaft

from

all machined surfaces.

Remove
passages,
etc. with

the

the amount of metal to be Follow the instructions of hone manufacturer. If coarse

are

by

ing ing
if

flange. If

no

burrs exist,

check

all pipe plugs which seal oil

stones

used

to start the

honing
so

the runout of the crankshaft

mount

then clean out

out all

all

the passages. Blow

operation, leave
that all
with

enough material

flange. Replace the flywheel

the

or

passages, bolt
air.

holes,

hone

marks can

be

removed

machine

the crankshaft flywheel face

compressed

Make
cylinder

sure

the

the

finishing
walls

hone
that
worn

which

is

used

mounting

flange

runout

is

threads

in

the

head
result
a

bolt in
a

to obtain the proper piston clearance.

excessive.

holes
may

are clean.

Dirt in the threads

and

Cylinder
marred
specified

are

severely
the
rebored.

cause

binding

and/or

beyond
be

RING GEAR REPLACEMENT

false torque
gear with

reading.

Use

tap

to

limits

should

Heat the defective

a

ring

true-up
deposits.

threads and to remove any

Before any
main
and

cylinder

blow torch

on

the engine side of the

off

bearing

caps must

is rebored, all be in place

gear, then

knock it

the flywheel.
when remov

After the

block has been thor

a

tightened to the proper torque so

Do

not

hit the flywheel

oughly cleaned, make cracks. Minute cracks

the naked eye may

check

for

that the crankshaft

not

ing

the

ring

not visible to

gear.

be detected
area with

Heat the
til the gear
onto
gear

new

ring

gear

evenly
sure

un

by
a

bearing bores will become distorted from the boring

operation.

expands

enough

to slip

coating the
mixture of

suspected

the

flywheel.

Make

the

25% kerosene light motor oil. Wipe the

and

and

75%

Rebore only the cylinder or cylin ders that require it. All pistons are
the
tons
same

part

is

seated

shoulder.

properly against the Do not heat any portion of

a

dry
of

weight, both standard and

immediately

apply

coating

oversize;
can

therefore,

various sized pis

zinc oxide

dissolved in

wood alcohol.

the

gear

to

temperature higher than

If

cracks are

500 F. If this limit is exceeded, the

temper
gear
will

be

removed

from the

ring

area.

become Replace

present, the coating will discolored at the defective

the

block

if

it

is

without up setting engine balance. Rebore the cylinder with the most wear first to determine the maximum
oversize.

be intermixed

teeth.

cracked.

If the cylinder

will not clean

1-40

GROUP 1-POWER PLANT

Straight Edge

Feeler Gauge

Feeler Gauge

1742-A

1743-A

FIG.
up

82 Outer Race
bored for

to

Housing

Clearan ce

FIG. 83-Rotor
matter

End

Play
Check the relief valve piston for free operation in the bore.

when

the

maximum

foreign
the

is

removed

from below

oversize piston recommended, replace

baffle

plate.

scores and

the block.

Check the
within

pan

Rebore the cylinder to proximately 0.0015 inch

quired

ap
re
will

damaged drain plug threads,

for cracks, holes, a loose

of

the

baffle,

and a nicked or warped gasket

oversize

diameter.

This

REPAIR OPERATIONS
(ENGINE IN
ENGINE

surface.

of

for the final step fin honing ish and pattern are obtained. Use clean sharp hones of No. 220-280 grit for this operation. For the proper use of the boring
allow enough

stock

so

the correct surface

pan

Repair any damage, or replace the if repairs can not be made.

PUMP
all parts

CHASSIS)
located
and

OIL

SUPPORTS
supports are on

Wash
them

in

a solvent and

dry
to

The front
each rear

thoroughly.

Use

brush

side

of

the

crankcase
at

the

equipment

follow the instructions

of

clean the

inside
dirt

support

of the

pump

housing

is located

the trans

mission

extension

housing.

the

manufacturer.

Only
be

experienced

and the pressure relief valve chamber.

personnel

should

allowed

to

per

Be

sure all

and chips are removed. of the

ENGINE

FRONT SUPPORT
engine

form
of

this work.
operation

Check the inside

After the final

the two

in

either

ing

and

the outer race

or excessive

pump hous and rotor for

of

The in

front The
a

support

is

shown

Fig.

84.

procedures
right

given

refinishing
wash

methods

de
pis

damage

wear.
surface

scribed and prior to

checking the

Check the mating

pump mating
cover

the

apply to lation.

either

or

left instal

ton

fit, thoroughly
particles,

the cylinder

for

wear.

If the

cover or

walls with solvent to remove all abra

surface
replace

is worn, scored,
the cover.
outer race

Removal

sive

then

the walls.

Check the

thoroughly dry piston fit (page

to correspond

grooved,

1. Remove

the

Measure the
clearance

to

housing

to engine retaining

insulator assembly bolts, and insula

nut

1-36). Mark the

to the
cylinders

pistons

(Fig. 82).
rotor

tor to underbody retaining

washer.

and

in

which

they

are

to

With the
over

assembly installed
a straight edge

be installed. When the refinishing of all cylinders that require it has been
completed and all pistons

in the housing,
the
rotor

place

If only

one

support

is

being

re

fitted,

thor
re

the hous assembly ing. Measure the clearance between

and
edge and

moved, loosen the other support.

2. Raise the
with

engine a

about

1-inch
wood

oughly
move

clean

the entire

block to

the straight
outer

the rotor and

jack
under

and

block
pan,

of

from the bearing bores, oil passages, cylinder head bolt holes, etc. Coat the cylinder walls
all particles with oil.

race

(Fig. 83).
race,
shaft and rotor are an assembly. shaft

placed move

the

oil

then

re

The

outer

the

insulator

assembly.

replaceable

only as Check the drive

clearance of

Installation

to

housing

1. Position the insulator

assembly.

bearing
OIL
OIL

by

measuring the
the I.D. of the

Install, but do
tor to engine

not

tighten,

the

insula
bolts.

PAN
PAN

AND

OIL

PUMP

O.D.

the

shaft and

lockwashers

and

housing
metal particles

bearing.
relief valve

Inspect the
pan.

spring for spring ten

not within

If both supports have been removed, install the bolts on the opposite side before proceeding with step 2. 2. Lower the engine, then install
the

Scrape any dirt or from the inside of the

old
gasket material

a collapsed or worn condition.

Scrape

all

Check the
sion.

relief

valve

from the
pan

gasket solvent

If the spring tension is

replace

underbody
and
nut

to
and

insulator

lock
nut

surface.

Wash the

in Be

specifications and/or

the spring is de

washer

tighten the

and

dry

it

thoroughly.

sure

all

fective,

the spring.

to 40-45 foot-pounds torque.

Tighten

PART 1-ENGINE

1-41

BRACKET ASSEMBLY

INSULATOR ASSEMBLY

INSULATOR BOLT

SPACER

1 74 5- A

746- A

FIG.

84 Engine Front Support

fold. Remove the heat tube.

FIG.

85 Engine Rear Support

choke

the insulator to engine bolts to 35-40 foot-pounds torque.

ENGINE REAR SUPPORT

automatic

3. Disconnect the
age at

accelerator

link

The engine in Fig. 85. Removal

the carburetor, the windshield

rear support

is

shown

1. Remove the
extension

support retainer to

housing
nuts,
the

and remove

bolts and washers, the support assembly to

flexible line at the vacuum and the booster pump vac uum line at the intake manifold fitting. Remove the carburetor fuel inlet line. Disconnect the primary wire at the distributor and the engine
wiper

2. Install the distributor, using the fines as guides to properly position the rotor and housing. 3. Install the radiator supply tank. 4. Connect the heater hose and
scribed

booster,

the radiator upper hose and install the automatic choke heat tube.

"Tee"

underbody bolts.

lockwashers,
extension

and

2. Raise

housing

temperature sending unit wire at the sending unit. On cars with power brakes, discon
nect

5. Connect the windshield wiper flexible line at the vacuum booster. Connect the booster pump vacuum line at the intake manifold. Connect
the
accelerator

linkage. Install the

the

fuel
ature

line.

Connect
and

distributor

slightly to relieve the pressure on the support assembly to underbody bolts,

retainer and

the power

brake line

at

the

in

primary wire,

the engine temper

wire.
spark

take manifold and at the flexible

line,

support assembly.

then release the line from the brack

ets on

sending unit distributor cap and

Install the
plug
wire

Installation

the left valve rocker arm cover the line.

assembly.

1. Raise
enough

the

extension

housing
support

and remove

On
nect

cars with

power

brakes,

con

to position the support assem

retainer.

bly

and

Install the
and

retainer

to

extension

housing

flat

washers,

lockwashers,

support assembly to lockwashers and nuts.

bolts, the underbody bolts,

ex

Remove the distributor cap and plug wire assembly. Disconnect the distributor vacuum line at the distributor. Scribe a line on the dis
spark

tributor
mark

housing

and

manifold

to

the position of the rotor and

2. Remove the jack from the

tension
port

housing,
torque,
nuts

retainer

then tighten the sup bolts to 25-30 foot

and

housing for installation. Remove the distributor hold down bolt and clamp, then remove the dis
tributor. Remove the radiator supply tank. Loosen the by-pass clamp and
slide

distributor

pounds

the support as

sembly
torque.

to

40-45

foot-pounds

brake line at the in take manifold and to the flexible line. 6. Fill and bleed the cooling sys tem. Connect the heater hose. Start the engine. Adjust the ignition timing and check all hose connections and gaskets for leaks. Connect the dis tributor vacuum line. Install the valve rocker arm covers and install the spark plug wires in the brackets on the covers. Be sure the spark plug wires for No. 7 and 8 cylinders are
the power

the

clamp back. Remove the

arm

INTAKE MANIFOLD
REMOVAL

valve

rocker

covers.
removal

properly positioned in the brackets. See Fig. 9 on page 1-48. Position

the wire
on

4. Complete

the

proce

dure
system.

by following

steps

and

loom in the retaining

clips

under

1. Drain the cooling

move the air cleaner.

Re-

Intake Manifold (page 1-16).

INSTALLATION

the left valve rocker arm cover. Install the air cleaner.

On
radiator

cars with power

2. Disconnect the

upper

the power
steps

hose at the radiator supply tank, and the heater hose at the intake mani-

1. Follow
under

2, 3, 4,

and

clips

on

brakes, install brake line in the retaining the left valve rocker arm

Intake Manifold (page 1-25).

cover.

1-42

GROUP 1-POWER PLANT

take
COAT GASKET WITH ENGINE OIL

on page 1-41. 3. Remove the retaining bolts from

Manifold"

the

top

center of

the grille and three

of

bolts from the bottom

and
push

the grille
grille

the

top

of

the

for

ward.

Carefully

remove

the camshaft

pulling it toward the front of the engine. Use caution to avoid damag ing the camshaft bearings.

by

INSTALLATION

slide

1. Oil the camshaft and carefully it through the bearings. 2. Follow steps 1 thru 3, under
Sprockets"

"Timing Chain
page

and

on

1-22.

seal

3. Replace the crankshaft front oil (page 1-23). Install the cylinder front cover, following steps 1 thru 7
lation"

under

"Cylinder Front Cover Instal on page 1-24.

valve

4. Install the hydraulic

and

lifters

the

intake

manifold and

related

parts

following

the procedure under

on page
oil

"Intake
the
and

Manifold"

1-25.

5. Install the
radiator

pan, the radiator,

supply tank, the

cleaner.

hood,

the

air

FIG.
CYLINDER
REMOVAL

86 Oil Filter Replacement

shaft sprockets

the

case.

cooling system. Start the engine

Fill and bleed Fill the crank

and adjust

the

HEADS

(Fig. 38). Remove the

ignition timing.

camshaft thrust
sprocket

button

and

spring, the

1. Drain the cooling system. Re move the air cleaner. Remove the in
take manifold and carburetor as an
assembly.

cap screw, the thrust button spring retainer, and the fuel pump eccentric. Remove the sprockets and

OIL

PAN

AND

OIL

PUMP

REMOVAL

Remove the
cylinder

exhaust mani

timing

chain as an

assembly (Fig. 24).

1. Drain the cooling

the
crankcase.

system

and

Disconnect the
at

radia

folds

and

the spark plugs.

INSTALLATION

tor upper
steps

hose

the radiator supply

pan
oil

head is to be removed, remove the ignition coil. 2. Remove the cylinder head bolts, then install the cylinder head holding

If the left

1. Follow

thru

under

"Timing
page

Chain

Sprockets"

and

on

Remove the oil screws and lower the

tank.

retaining
to the

pan

1-22.
crankshaft

underbody

cross

member.

Position

2. Replace the
seal

front

oil

the crankshaft so the counterweight

will clear

fixture (Fig.
head
off

21).

Lift

the
not

cylinder

(page 1-23).
cylinder

the oil pan and move the

the

block. Do
and

tween the

head

pry be the block. Re

gasket.

3. Install the

front
under

cover

pan

forward.
coil

move the cylinder

head

following
1-24).

steps

1 thru 4

"Cyl

2. Remove the

retaining bolts
the way.

inder Front Cover Cyl

4. Install the Install the
water

Installation"

(page

and position the coil out of

INSTALLATION

1. Follow

steps

1, 2, 3
1-24.
and
spark

under

crankshaft

damper.

Install the engine lifting brackets and sling. Raise the engine high enough
to place tension on the engine mounts.

inder Head
exhaust plugs.

on page

pump, pulley, and

2. Install

the

intake manifold, the

the
spark wires.

fan
pan.

as

an

assembly. and

Install the
the pump,

oil

Remove the
engine

engine

front insulator to
en

manifolds,

Install

adjust

drive
the

retaining bolts. Raise the

enough

Connect the

plug

belt(s).
radiator

Install

the

fuel

gine
of

high

to permit removal

CYLINDER

FRONT

COVER

Fill
the

and

supply tank, and the hood. bleed the cooling system. Fill

the oil pump retaining the oil pump.

bolts,

then

remove the
and

bolts. Remove the

oil pan

AND TIMING
REMOVAL

CHAIN

crankcase.

Start the fast idle

and

engine

and

adjust

the

ignition timing. Operate

and check all gaskets

INSTALLATION

the engine at

1. Drain the cooling system and the crankcase. Remove the hood, air
cleaner, radiator, fuel pump,
radiator

hose
leaks.

connections

for

1. Raise
allow

the

engine

enough

to

installation of the oil pump and the oil pan. Position a new gasket on
the oil pump
pan.

supply tank,

water

pump,
pan.

crankshaft

CAMSHAFT
REMOVAL

housing
oil

and on the oil oil pan

damper,
retaining
shaft

and

the oil

Place the
cross

pump in the

2. Remove the

cylinder

front

cover

and position
steps

the oil pan on the under

member.
shaft

bolts,

then remove the cyl

1. Follow Chain

and and

under

body

Insert the
oil

oil

inder front

cover.

Remove the

crank

"Cylinder Front Cover

Removal"

Timing
"In

pump drive

into the

pump

front

oil slinger.

Align the tim

in this
3
and

section.

housing

and

ing

mark on

the camshaft and crank

2. Follow

steps

under

shaft as an assembly.

install the oil pump and Do not attempt

PART 1-ENGINE

1-43

MUFFLER
MUFFLER

FRONT CLAMP

REAR CLAMP

MUFFLER INLET PIPE FRONT SECTION ASSEMBLY

MUFFLER

OUTLET

PIPE

MUFFLER

INLET PIPE

REAR SECTION

FRONT BRACKET

174 7- A

FIG.

87 Exhaust System
position

to force the pump into

will not seat readily.

if it
shaft

tion on the adapter (Fig. 86). Hand

tighten the

valve on

the right exhaust

a new gasket on

manifold.

The drive

filter

until

the

gasket con advance

Position
gas pipe

the exhaust

hex may be intermediate

misaligned with

the dis

tacts the adapter

face,

then

control

valve.

Position the inlet

tributor shaft. To align, rotate the

shaft

it 14 -turn.
and check

assembly

on the exhaust mani

into

new

posi

tion. Tighten the oil pump retaining screws to 23-28 foot-pounds torque.

3. Operate the engine at fast idle for leaks. If oil leaks are
perform

fold

studs and on

the extension of the

mufflers.
place.

evident,
pairs

the

necessary

re

front clamp into Connect the inlet pipe to the

Slip

the

2. Hold
against

the

oil

pan

in

place

to correct the leakage. Check

exhaust nuts

manifolds

and

tighten

the

the cylinder block and install

of

the oil level and

necessary.

fill the

crankcase

if

to

23-28

foot-pounds torque.
pipe

oil pan.

retaining screw on each side Install the remaining

them

the

Align the inlet

assembly

and

screws

tighten the clamps.

and tighten
ward

from the

center out

EXHAUST SYSTEM
The
Fig. 87.
MUFFLER
exhaust system

to 12-15 foot-pounds torque.

is

shown

in

MUFFLER AND OUTLET PIPES

3. Lower the engine, then install the engine right and left front support retaining bolts. Tighten the bolts to
40-45
the

The
INLET PIPE REPLACEMENT
muffler

procedure applies to either a

right or

left

assembly. muffler

foot-pounds torque.

Remove
sling.

1. Loosen the

engine

lifting

bracket

and

The right and left front sections are

piece.

inlet
as

inlet
the

pipe

pipe

rear

clamp,

then spread
off

serviced

one

Install the
tor
upper

coil and connect the radia

and slide

it

the muffler.
of

clamp Remove
rear

hose. Fill the cooling

the
crankcase

sys

the
muffler

1. Loosen the

inlet

lower half
pipe.

the

muffler

pipe

tem.

Fill

with

the

clamp.

proper grade

and

quantity

of engine

oil.

Operate the

engine and check

for

front support clamp bolt and slide the clamp off the support. Disconnect the inlet pipes at the exhaust manifolds.
Remove the muffler inlet bly. Remove the exhaust
pipe assem
gas control

Remove the

muffler

from the

inlet

2. Position the
outlet pipe

new

muffler

and

leaks.

assembly
muffler

on

the inlet pipe.

Slide

the

OIL

FILTER
as

valve

Replace the filter

follows:
the filter.

1. Place

drip

pan under

from the right exhaust mani fold and discard the gaskets. 2. Position the clamp on the front
section of the new

inlet

pipe until the slots are

extension
must not

forward into the in the muffler blocked. The overlap

IVa inches.

be

greater than

filter from the adapter. Clean the adapter filter recess. 2. Coat the gasket on the new filter
Unscrew the
with

inlet

pipe.

Connect
Place
a

Align the
sembly.

muffler and outlet pipe as

the

front

and

rear

sections.

new gasket on

the exhaust manifolds,

oil, then

place

the

filter in

posi

then position the exhaust gas control

Position the muffler inlet pipe clamp and install the retaining bolts. Install the muffler rear clamp.

1-44

GROUP 1-POWER PLANT

PART 2
Section

IGNITION SYSTEM
Page

1 2
3 4

Trouble Shooting Ignition System Testing Distributor Tests, Adjustments,

Minor Repairs
and

1-44

1-45
1-49

IGNITION

SWITCH

acc^JTXam

/l^.

SPARK PLUG

I
r

Distributor Overhaul
purpose

1-52
system

S*-**K*

DISTRIBUTOR

%&>L

The

of the ignition
voltage
system

is to
the

transform
electrical

low

electricity from
to surges of

supply

high

voltage electricity and to

distribute
plug

this

high

voltage to the proper spark

at the right

time.

The ignition

system

consists

of

primary (low voltage) and a second ary (high voltage) circuit (Fig. 1). The

PRIMARY CIRCUIT

battery, ignition
cuit resistor,

switch, primary cir

SECONDARY CIRCUIT

1182-C

primary windings of the ignition coil, breaker points, and the

FIG.

1 Ignition Circuit

in the primary circuit. The secondary circuit is composed of the secondary windings of the igni tion coil, distributor rotor, distribu tor cap, high tension wires, and the
condenser are
spark plugs.

TROUBLE SHOOTING
Ignition
system troubles are caused

IGNITION

TIMING
can

When the breaker

the

points are

closed,
current

failure in the primary and/ or the secondary circuit, or incorrect igni

by

Incorrect ignition timing caused by:

1. 2. Distributor
shaft

be

primary

or

low

voltage

tion timing.

flows from the battery through the ignition switch to the primary wind ings in the coil, then to ground
through
the
closed

PRIMARY

CIRCUIT
or

Timing incorrectly adjusted. bushing and/or

a

A break down

energy loss in the

worn, or

bent distributor

shaft.

breaker
points

points.

When the breaker

magnetic windings

open,

the

field built up in
of
windings

the primary the

primary circuit can be caused by: 1. Defective primary wiring. 2. Burned breaker points or im properly adjusted breaker points. 3. A defective coil, resistor, or con
denser.

3. Defective
tem.

vacuum advance sys

4. Defective
plugs

centrifugal

advance.

5. Preignition
of

(caused
plugs,

the coil moves through

of coil

by
etc.

spark

the

the wrong heat range), im

adjusted

secondary producing high

voltage current

voltage current.

High
time

properly

is

produced each
open.

the

breaker

points

The high
coil

SECONDARY

CIRCUIT
or

voltage

flows through the lead

spark

high

A break down
secondary
or plugs circuit or

energy loss in the

If the cause of engine trouble has been traced to the ignition system (page 1-7), refer to the trouble in

tension
where of

to

the rotor

distributor cap distributes it to one

the

1. Fouled

be caused by: broken spark plugs,

can
adjusted.

Table 1
troubles

and

under the trouble.

the

distributor
peated
engine.

cap.

plug terminals in the This process is re

power stroke of

incorrectly

are

the items listed The causes of the listed in the order of

check

for every

the

2. Defective high tension wiring. 3. High-tension leakage across the

coil, distributor cap, or
rotor.

their probable occurrence;

items should be order listed.

the

checked

therefore, in the

TABLE

1 Ignition System Trouble Shooting

To determine if the

cause

of

the

Distributor Rotor.

cap.

trouble is in the primary or the sec

ondary circuit, pull the coil wire from the top of the distributor and

Spark plug

wires.

ENGINE

CRANKS
BUT

hold it approximately Ve inch from the cylinder head, then with the igni
tion on and the engine
check

If there is
spark, the

no

spark of

or

weak

NORMALLY,
WILL
NOT

cause

the

trouble

is

turning

over,

START

for

spark.

If the

spark

is

probably in the:

good, check the

ignition timing.
good and

Primary

circuit.

If the
tion
of the

spark

is

the igni
the cause

timing is

not at

fault,

Coil to distributor high tension lead.

Coil.

trouble is probably

in the:

PART

IGNITION SYSTEM

1-45

TABLE

1 Ignition System Trouble Shooting (Cont'd.

Check the:
Breaker
points.

ENGINE STARTS, BUT FAILS TO KEEP RUNNING

Resistor for

an open circuit.

Check for leaks in the high

wiring.

tension

Spark

plugs.

MISSES STEADY AT ALL SPEEDS. If the miss is isolated in

a particular

Secondary
Coil.
Spark

wiring.

cylinder,

perform a spark

plugs.

test on the ignition lead of that cylin

Check
across cap.

for high

tension

leakage

der.
If
of a good spark

trouble

does not occur, the is in the secondary circuit

the coil, rotor, or distributor

the system, check the:

MISSES AT IDLE ONLY. Check

the:

ENGINE RUNS, BUT MISSES

a

Spark plug wire. Distributor cap.

If
a

Coil. Condenser.
Breaker
points.

good spark

occurs, check the

spark plug.

If the

spark

is

not at

fault,

mechanical

component of
at

the en

Rotor.
Ignition wiring for leakage. Distributor shaft for excessive
play.

gine

is probably

fault. AT

MISSES ERRATICALLY ALL SPEEDS. Check the:

Breaker
points.

Spark

plugs.

Condenser.
Check the:

Distributor

cam

for wear.

Breaker

points.
advance.

POOR ACCELERATION

Ignition timing. Spark plugs. The cause of this trouble usually lies in the ignition system only when
the trouble
peratures. exists

Distributor

Rotor.
Distributor Distributor
play. advance.

ENGINE DOES NOT DEVELOP FULL

at

all

engine tem

shaft

for

excessive

POWER, OR HAS
POOR HIGH SPEED PERFORMANCE

Check the:

Ignition timing. Coil. Condenser.

Distributor

cam.

Spark

plugs. points.

Breaker
Spark

EXCESSIVE FUEL CONSUMPTION ENGINE OVERHEATING

Check the: Ignition timing.

plugs.

Distributor

advance.

Check the ignition timing.

IGNITION SYSTEM TESTING

A
complete check of

the ignition
and

and

the contacting surfaces on

the

system

includes the

battery

battery,

distributor, primary and secondary wiring, and the spark plugs. This section describes the tests
cables, coil,

engine, and relay are clean. Tighten the cables securely upon in
stallation.

cap,

Clean the inside of the distributor and inspect it for cracks, burned
or permanent carbon

contacts,

tracks.

Test the
all

battery (Group 7,

Part 1). Inspect

worn

for
and

all

these units except the

battery
supply Part 1.

the primary wiring for

the distributor.
part of

The battery, be
electrical

insulation, broken

strands,

and

from the sockets. Inspect the rotor for cracks or a burned tip. Replace the cap and/or rotor if they are defective.
or

Remove dirt

corrosion

cause

it is system, is

the

covered

in

Group 7,
covered

Distributor testing is tion 3.

in Sec

loose or corroded terminals. Replace any defective wiring. Make sure all connections are tight. Remove the coil to distributor high tension lead
the spark plug wires one at a time from the distributor cap and
and

PRIMARY CIRCUIT RESISTANCE TEST primary cir checking for excessive voltage drop from the battery to the coil and from the coil to ground. Ex
cuit consists of

complete test of the

PRELIMINARY Inspect the

CHECKS
corrosion re

battery for battery

due to
with a

acid and

dirt. If necessary

move and clean the

and cables

baking

soda solution and wire

brush. Be

sure

the cable connectors

spark plugs. Inspect the ter for looseness and corrosion. Inspect the wires for breaks and cracked insulation. Replace all de fective wiring.
minals

from the

cessive

circuit will

drop in the primary lessen the secondary out put of the ignition coil, resulting in hard starting and poor performance.
voltage

1-46

GROUP 1-POWER PLANT

VOLTMETER
VOLTMETER

1 173-C

1175-C

FIG.
the

2 Battery

to Resistor Test

FIG.
tension
engine

3 Battery
the

to Switch Test

The

following

tests are made with

lead

at the coil and crank

high tension lead. Follow the instruc

tions
when

ignition

switch on and the

breaker

while

observing
not

the

voltage

of

the

test

set

manufacturer

points closed.

drop. It If the
and

should

exceed

0.1

volt. clean

making the test.

voltage

BATTERY

TO COIL TEST the

voltage
at

drop

is excessive,

Check

tighten the terminals or replace

as necessary.

COIL
Coil tests
can

the

battery

terminal of the coil.

If the voltage is below 8.5 volts, it will be necessary to make the following checks to de
termine the point of high
resistance

wiring

be

made with the coil

installed
BATTERY

on the engine or on a

test set.
sec

TO

GROUND TEST
positive

The
of

coil'

tests

include

coil

heat,

Connect the
voltmeter of the

lead

the

to the distributor terminal

in the battery to coil circuit. Connect the negative lead of

meter

ondary continuity, and coil capacity. A coil may break down after it has
reached

coil,

a volt

ground. exceed

to the
and

battery
the

terminal of the

and the negative lead to The voltage drop should not 0.1 volt. If the voltage drop is

fore,
the

coil

operating temperature; there heat test is made to test

at operating temperature. secondary continuity test is

ceil coil

resistor

positive
of

lead to

the

excessive,
each of

test

the

voltage

drop

of

The

positive

terminal

the

battery
volts or

the

following:
wire.

performed windings

to test the coil secondary

(Fig. 2).

1. Coil to distributor

If

the voltage

drop
is

is 0.2

less, tery
the

the primary circuit from the bat to the

voltage
resistor

and

2. Distributor primary terminal the movable breaker point.

3. The
movable plate.

for high resistance. The coil capacity test is made to determine the
condition of the windings of

the coil. the in

satisfactory.

If breaker
point and

Perform
structions

all tests

following
set

drop

exceeds

this

limit,
volt

leave
meter

the

positive

lead

of

the

the

breaker

of

the

test

manufac

turer.

connected of

to the positive ter

and

4. The breaker
tributor housing.

plate

and

the dis
REMOVAL

minal

the

battery
ignition
change

touch
coil

the ter

voltmeter negative minal

lead to the
switch

5. The
engine

distributor

housing

and

Disconnect the high tension lead

and

of the

(Fig. 3).
touch

ground.

the primary
coil

leads from the

mounting

coil.

If there is
the

no

in the reading,

Remove the

screws and

the circuit is satisfactory.

voltmeter

Next,

SPARK

INTENSITY
one spark

remove

the coil.

negative

lead to the
switch a

Disconnect

plug

wire at
adapter

INSTALLATION

battery

terminal of the

ignition

time and install a terminal

Place the

coil

(Fig. 3). If the reading

excessive

drops,

there

is

in

position and

install

in

the wire terminal. Hold the adapter

resistance

in the

switch.

approximately

Vie inch from

the

the ex
engine.

the mounting screws. Insert the high tension lead into the coil socket. Push the
weather
seal

Check the primary

resistor

by

con

haust

manifold and crank

tight

against

necting an ohmmeter across its termi nals (Fig. 4). Disconnect the battery
wire at

the

The

spark should

jump

the gap
of all

regu

larly.

the

resistor

to

prevent

damage

If the

spark

intensity
and

leads is
ro

to the
ance

ohmmeter.

The

Connect the primary wires to the coil. Be sure the wires are prop erly installed.
socket.

specified resist

satisfactory, the coil, condenser,

is 1.3-1.4

ohms.

is

over or under

If the reading this limit replace the in the starting

tor, distributor cap,

sion cables are

the high ten

satisfactory.

RESISTOR
The
resistor

probably

(Fig.

6) is

checked

for
ex

resistor.

If the
resistance

spark

is
a

good

at

only

some

excessive resistance as
plained under

Check the
ignition

leads,
of the

perform

high

resistance

test

"Battery

previously To Coil

Test."

circuit

by

voltmeter positive

connecting the lead to the positive

and

faulty
or

leads.

If the
weak

spark

is

equal at all

leads, but
a

SPARK PLUGS
An 18-millimeter
spark

terminal of the

battery

the

nega

intermittent,
and

make

high
a

plug (Fig.
not require

tive lead to the battery terminal of the coil (Fig. 5). Disconnect the high

resistance check of

the coil, distribu

7) is

used.

This plug does

tor cap,

the

coil

to distributor

gasket.

PART

2 IGNITION

SYSTEM

1-47

OHMMETER
VOLTMETER

JE"2el
1 1 74-C

FIG.

4 Resistor Test

1 1 72-C

FIG.

5 Starting Ignition Circuit Test

TERMINAL

INSULATOR

**"*

SHELL

60

TAPERED SEAT

GROUND E1ECTRODE

1771-A

FIG. 7-1 8-Millimeter Spark Plug

REMOVAL

Pull the

wire off each spark

plug,
re

FIG.

6 Resistor

and clean the area around each spark

plug
move

with

compressed

air,

then

the spark plugs.

CLEANING AND INSPECTION

Examine the
spark

firing

ends

of

the

plugs, noting the type of de posits and the degree of electrode

erosion.

The

various types of spark

and

plug

fouling

the normal condi

tion of the spark plug after usage are

shown

in Fig. 8. (Fig. 8) is usually iden sludgy deposits. These

oil

Oil
tified
are

fouling by wet,

traceable to excessive
combustion
rings and

entering
through
excessive
guides

the

chamber

worn

pistons,
or

clearance
and

between

the valve

loose bearings. 8) is usually iden tified by dry, black, fluffy deposits which result from incomplete com bustion. Too rich a fuel-air mixture
stems, or worn Gas fouling (Fig.
NORMAL CONDITIONS

NORMAL CONDITIONS

can

cause
a

1179-B

addition,

incomplete burning. In defective coil, defective

or
a

FIG.

8 Spark Plug Visual Inspection

breaker points,

defective igni
sup-

tion cable can reduce the voltage

1-48

GROUP 1-POWER PLANT

plied to

the spark plug

and cause mis

firing. Burned or overheated spark plugs (Fig. 8) are usually identified by a white, burned, or blistered insulator
nose and

badly

eroded electrodes.

efficient

engine

cooling,

In improper

FIRING ORDER

fuel,

ignition timing, the wrong type of or loose spark plugs can cause
general overheating.

Normal
where

conditions

(Fig.

left)

regular or unleaded gasolines used are

have been

usually identified
pow

by

a rusty-brown

to grayish-tan,

dery deposit
sion,

and minor electrode ero

indicating

proper

ignition 8

and

combustion conditions.

Normal
where

conditions

(Fig.

right)

highly leaded
used are

gasolines

have

been

usually identified by white, powdery deposits. If the spark

plugs are

cleaned and

at

recommended

intervals
have little

normal

service

condi

tions are encountered, these deposits

effect on

plug

performance.

However,
to

prolonged

high-speed, high

load operation will fuse these deposits form a yellowish glaze. At high temperatures, this glaze may be con ductive, resulting in spark plug "miss
ing"

FIG.
Test for
insulator

9 Ignition Wiring Installation

leakage
coating
at

compression

the

with a probe.
separation

The

probe

seal.

or

fouling.
plugs on
a

Apply

of oil

in the

conductor.

may cause a A spark

service.
and

Clean the
cleaner,

sand

blast

to the shoulder of the plug where the

insulator
and

projects

through the

following

shell,
plug,

the manufacturer's

plug wire set is available for At regular intervals, clean

spect the wires and

in

to

the

instructions. Do
of

not

the abrasive blast

prolong the use as it will wear

carbon
and

top

of

the

spark

for

cracked

insulation
or replace

where
nal

the center electrode and termi

loose terminals. Repair

project

the

insulator.

Remove

from the insulator. Place

under pressure.

the wires as required.

REMOVAL

other
a stiff

deposits from the threads with wire brush. These threads are

the spark plug

age

Leak Disconnect
spark
plugs remove

is indicated

by

air

bubbling
the
satis

through the oil.

compression
spark plug.

the means of carrying the heat away from the spark plug. Any deposits
will retard

If the test indicates

replace

the

wires

from
cap.

the

leakage,
spark

and

distributor from
molded

To Do

the

heat flow from the

cylinder

If the

plug is

the

wires

the

spark

spark

plug to the

head,
and

caus
pre-

factory,

wipe

it

clean.

plugs,

grasp the
the
wire

cap

only.

not pull on

wire as

this may sepa

ing

spark

plug overheating

INSTALLATION

rate area around

the
or

connection

inside the Pull

the
on

ignition. Clean the electrode file. Dress the small

secure surface with a
electrodes

Clean the
plug
port

the

spark

cap
the

damage the

weather seal.

to

insure

proper

seating.

wires

from the brackets

to

Install the

spark

plugs, then tighten

valve

rocker arm covers and remove

flat

parallel

surfaces

on

both
not as

them to 15-20

foot-pounds torque.

the wires.
INSTALLATION

the center

and side electrode. electrode

result.

Do

file the

ground

too thin

pre-ignition

may

HIGH TENSION WIRES

The high tension
wires

(SECONDARY)
wires

1. Insert

each

wire

in the

proper

After cleaning, carefully for

sulators,
other
signs

examine

cracked pitted

or

plug broken in
or as

the

include the

connecting the distributor cap

center terminal of the
center

badly
of

electrodes,

to the spark plugs and the wire con

distributor cap socket. Be sure the wires are forced all the way down into their sockets. The No. 1 socket is

failure.

Replace

necting the
tributor

dis

required.

cap to the the ignition coil.

spark

terminal of

identified on the cap. Install the wires in a counterclockwise direction in the

ADJUSTMENT

firing
wires
which

order

(1-5-4-2-6-3-7-8) starting

Set

the

plug

gap
the

(0.032-

The
radio

high

tension

are

the

at

0.036 inch)
electrode.

by bending

ground

TESTING

Set the
plugs on a

gap,

then

test

the

spark

filter out the high frequency electrical impulses that are the source of ignition noise interference. The wires can be identi Resistance" fied by the words "Radio
resistance-type
stamped on each cable.

1 socket. Cylinders are from front to rear-right bank, 1-2-3-4; left bank, 5-6-7-8. 2. Remove the brackets from the
the
numbered old spark

No.

plug

wire

set

and

install in the
arm

them on the

new set

in the

same rela

testing

machine.

Compare
a
new

The

resistance

tive position. Install the wires

the sparking efficiency of the cleaned

and
plug.

of each wire should not exceed

24,500

brackets
covers

on

the

valve

rocker

regapped

spark

plug

with

Ohms. When checking the

of

resistance

(Fig.

9),

then connect the wires

Replace the plug if it fails to

requirements.

the

wires or when

setting ignition
the
wires

to the proper spark plugs.

coil

meet

timing,

do

not

puncture

high tension lead. Be

sure

Install the No. 7

PART

2 IGNITION

SYSTEM

1-49

B.T.C.CONVENTIONAL DRIVE AND OVERDRIVE

B.T.C

CRUISE-O-MATIC

1571-A

<

,1772-A

FIG.
spark

10 Timing Marks
spark

FIG.
plug
and

11 Checking Ignition Timing

11). The timing is
wise rotation of and retarded advanced

plug wire is positioned in the brackets as indicated in Fig. 9.

the other two leads of to the

by

clock

the

timing light

battery

ter

the distributor

body,

minals.

IGNITION

TIMING

by

counterclockwise ro

has a crankshaft dam per having five timing marks (Fig. 10). The first long mark represents top dead center (T.D.C.) and each The
engine

2. Clean the dirt from the timing and if necessary, chalk the proper mark and the pointer to im prove legibility.
marks,

tation.

been properly set,

tributor vacuum

5. After the ignition timing has connect the dis

line,

then check the

succeeding
center
should

6, 8, 10,
be

2, 4, top (B.T.C.). The initial timing

mark
represents

respectively, before
3

3. Operate the engine at idle speed. Be sure the engine is idling below 550 rpm so that there will be no cen
trifugal
should advance.

distributor to determine if the ad vance mechanism is operating. To do

this, hold the timing light

so

that the

set

at

B.T.C.
with

The timing light

timing
vance

marks and pointer can

on

con

ventional
6

drive
on

or overdrive units and

cars

B.T.C.

Cruise-O-

Matic.
CHECKING TIMING WITH A TIMING
LIGHT

flash just as the proper mark lines up with the timing pointer, indi cating correct timing. The operator's eye should be in line with the center of the damper and the timing pointer.
4. If the
the
proper pointer

and accelerate the engine.

be seen, If no ad

is evident,
probable
at

one of the

following
vacuum vacuum

is the

cause;

no

available advance

the

distributor,

timing
do

mark and

diaphragm connected from the

centrifugal advance

leaking
not

or dis breaker plate,

1. Disconnect the distributor

vacuum

timing

not

line up,

line,

then connect the

timing

rotate the
mark and

distributor

until the correct

properly, breaker

plate

functioning binding in the

light high tension lead to the No. 1

the pointer are in line (Fig.

housing

or on the

bushing.

DISTRIBUTOR
This
ments,
section covers

TESTS, ADJUSTMENTS,
indicated.

AND MINOR REPAIRS

the engine and check

the

and

minor

repairs

tests, adjust for the

it

on a

distribu
and

tor test set

DIAPHRAGM LEAKAGE AND FREENESS
under

following

the

instructions

distributor.

"Spark

Advance Tests

OF OPERATION

Adjustments."

SPARK

ADVANCE

CONTROL

These tests
on a

can

be

made with

the

Check the
nism

vacuum advance mecha

of

MECHANISM

distributor installed
advance
control

on the engine or

for freeness

operation

The

spark

distributor test for

set.

mechanism should

be tested

during
is

sufficient

an engine

The tests are tune-up. How

by

manually rotating the breaker plate in the direction of rotation. Do not

rotate

tune-up,

when

the distributor
new

over
or

ever, if there are indications that the

spark

the

plate

hauled,

on

installation,
trouble

advance
remove

is

by pushing
points,

on

the

not

functioning

condenser or the
or

whenever

spark

advance

is

properly,

the distributor from

other

suitable

hook instrument in the

use a

1-50

GROUP 1-POWER PLANT

breaker point and adjustment The breaker plate should turn

out

slot.
with

speed

to

where

there

is

no

advance

unit,

and

can

be

replaced

without

and zero the advance

scale.

Increase for

removing
engine.

the

distributor

from

the

binding
binds,
and

and return to

its

original

the

speed

to

the

value

specified

position when released.

plate

If the breaker

the

first

advance

reading listed in the

correct advance at this

Breaker
cleaned,
vals.

points should

remove the plate.

Clean,

specifications.

If the

and adjusted at regular

can and
a

be inspected, inter
with

inspect,
To
age:

lubricate the distributor. diaphragm for leak

to read

is

not

indicated
and

rpm, stop the

the

Points

be
stiff

cleaned

check the

Adjust the
the

vacuum gauge

primary spring bracket to change tension (Fig. 12). Bend the bracket away from the distributor
and
advance.
shaft

distributor

bend

chloroform

bristle brush.
assembly

Replace the breaker if the

points contacts
metal

point

are

badly

burned

or

ing

highest vacuum the instructions

on

possible
of

follow
test
set vacuum

to

decrease
to

advance

excessive

transfer

the

toward

the

shaft

increase

is

evident.

between the Metal transfer is

when

manufacturer.

Install

the

hose

the

diaphragm

vacuum

line

fitting. The vacuum gauge reading should not fall off when the vacuum
is
if
applied to the
no

The primary spring is the spring that is under tension when the distributor shaft is not rotating. To determine
slot and
which

considered or
exceeds

excessive

it

equals

gap setting. Burned breaker points are

and

the

gener

leak

by

the

diaphragm assembly If a leak is indicated test, replace the diaphragm

exists.

sion, insert

spring is under ten hook into the adjusting

each
will

ally the result of an

oil

accumulation of

dirt

on

the

points.

This is

move

spring. under

The

sec

ondary spring
sion

be

less ten

usually caused by oil bleeding from the distributor base bushing onto the
points,

assembly.

than the primary

the

spring. advance

by

excessive or

improper
to
clean

cam

BREAKER

PLATE

WEAR

TEST
will
cause
angle

2. Check
utor

minimum

lubricant
points,

being

thrown off onto the

neglect

point again, then operate

the distrib

and/or

the

A
the

worn

breaker
point

plate
and

at

the specified rpm to give an

points periodically.

breaker

gap

dwell

advance

just below the is

not

maximum.

If

Excessive
the

metal
points point

transfer

between
caused voltage

to change as engine speed and load

conditions are varied.

this advance the

to specifications,
and

breaker

is generally
alignment,

Install
set

the

distributor
the

on

a
of

test the

following
set

instructions
plate

test

manufacturer.

Attempt

to

"rock"

the

breaker

stop secondary spring bracket to give the correct advance. The secondary spring is the spring that is not under
tension (is slack)
shaft
when

distributor

bend

the

by

incorrect

regulator
radio

condenser

setting that is incorrect, a installed to the dis

of the

tributor side
condenser
extended

coil, an

ignition
or
other

by

applying

the distributor

of

improper capacity
at
speeds

light thumb pressure, alternately, to each side of the breaker plate (mov
able section or
should

is

not rotating.

operation

inner

race).

be

repeated

with

The test the breaker its

nor

3.
other

Recheck the
two
as

zero point and

and

the

than normal.
REMOVAL

points

make

adjust

plate

in

ments

required.
at

various positions of

Next,

check

the

advance

all

mal travel. changes

If the dwell
than

points

listed in the

angle

reading
while

more

4 degrees

specifications.

Operate the distributor

speed range.

Disconnect the primary and con denser leads. Remove the screws that
secure

"rocking"

the

breaker plate, the bush

replaced.

both up

and

down the

the

ing

should

be

VACUUM ADVANCE
AND

the breaker point assembly to breaker plate, then remove the breaker point assembly.
INSTALLATION

SPARK

ADVANCE

TESTS

1.
rpm

Operate the distributor

and zero

at

1000
scale. vac

ADJUSTMENTS

the

advance

The

spark

advance

is

Check the
checked

advance
given

at

the

first

to
uum

ser

determine
advances
speed and

if the

ignition timing

setting

in

1. Place the primary leads on the breaker

and conden point assem

the specifications.

in

If the
the

advance

proper relation to engine

load.
on a test set

spacing

washers

is incorrect, change between the

spring
and
nut.

primary terminal. Install the lockwasher and nut, then tighten the

bly

nut securely.

vacuum

chamber

Mount the distributor

and calibrate

After

the

test

set

following

installing
the

instructions of the manufacturer. Check the dwell angle. If the dwell is

the
not

ers, position
tighten

removing the wash the gasket in place and

or

2. Position
sembly
sure

the

breaker

point

as

nut.

The

addition

of

breaker plate, then install the hold down screws. Make

on

the

between
not

26-281/2

washer will

decrease
a

advance and
will

the

the ground wire

screw

or

the point
removal

of

washer

increase

the

gap it
adjust
arm

within

0.014-0.016
(17-20

inch,

advance.

ment one point of the curve

should

slot.

terminal is on furthest from the adjust Adjust the breaker point

the points.

Check the breaker

ounces),

When

is

ad

gap.

spring
adjust

tension

and

it if

justed,
Do ring
not

the others
change

be

checked.
rpm
set-

necessary.

the

original

The
systems.

distributor
operated

has two
spark

inde

pendently

advance

setting.

Each

system

is

adjusted

separately.

Adjust the

going to a different vacuum If they arc not within limits, it indicates incorrect spring tension or
when

Breaker Point Gap. The breaker can be adjusted with the dis tributor installed on the engine or
points

on

distributor test

set.

centrifugal ad

leakage in the
and/or

vacuum

chamber

New

Breaker Points. When

points are
a

new

vance

before adjusting the

vacuum

line.

breaker
gap

installed,
gauge.
until

check

the

advance.

with

feeler
cam

Rotate the
rubbing lobe.

BREAKER
CENTRIFUGAL ADVANCE

POINTS
point

distributor block
gauge

the

1. Operate the distributor in

direction
wise)
spark

the

of

rotation

(counterclock
rpm

assembly con sists of the stationary point bracket assembly, breaker arm, and primary
wire

The breaker

rests on the peak of a cam

correct

Insert the

blade

of

feeler
points

between

the

breaker

and

increase the
to

until the

terminal.
on

begins

advance.

Reduce the

mounted

the

The assembly is breaker plate as a

(Fig. 13). The correct gap should be 0.014-0.016 inch. If the fit is loose or

PART

2 IGNITION

SYSTEM

1-51

CENTRIFUGAL ADVANCE ADJUSTMENT HOLE

Screwdriver

Tool-

12150-D

FIG.
128-A

13 New Breaker

Point

Gap

Adjustment

FIG.

12 Centrifugal Advance Adjustment

Adjusting

Wrench 12150-D

CONTACT AREA CENTERED

CORRECT ALIGNMENT

CONTACT AREA NOT CENTERED

MISALIGNMENT

OF CENTERS

CONTACT AREA

NOT CENTERED

MISALIGNMENT OF

POINT FACES

1129-B

p| G.
if

14 Breaker Point Alignment

FIG.

15 Aligning Breaker Points

manufacturer. The dwell angle should be 26-28,/2. Check the point align

there

is binding, loosen the

lockscrew
and

station

ary

point

adjust

the

used

Used Breaker Points. If the gap of breaker points is being checked,

a

gap (Fig. 13). A light film

non-fiber

use
of

dwell It is
gauge

meter to test the not advisable

dwell
use
a

ment, then

set

the

ignition timing.

high-temperature,

angle.

to

grease should when new

be

applied

to

feeler
gap

to adjust or to

check

the

BREAKER POINT ALIGNMENT

vented-type breaker points be accurately aligned and strike squarely in order to realize the full
must

the
are

cam

breaker

points

of

used

breaker

points

because
points

The

installed. Do

not use engine oil cam.

to

the roughness of the

make a

breaker

lubricate the distributor

the breaker the ignition
point

Check

alignment

then set

sible.

gap reading or setting impos Check the dwell angle following

of the

advantages provided
and

by

this

timing.

the

instructions

dwell

meter

assure

normal

point

life.

design, Any

1-52

GROUP 1-POWER PLANT

LESS TENSION

BREAKER POINT TENSION SPRING

MORE TENSION

17-20 OUNCES

1773-A

11 69- A

FIG.

16 Spring Tension
of

FIG.
surfaces
until the
open

17 Spring Tension Adjustment

start

misalignment

the

point

breaker

points

just

to

DISTRIBUTOR SHAFT END PLAY Remove the distributor from the Place the distributor in the holding tool and clamp it in a vise. Push the distributor shaft upward as far as it will go, then check the end
engine.

will cause premature wear, overheat

(Fig. 16). If the tension is

the spring tension.
adjust the

not

ing

and pitting.

within specifications

(17-20 ounces),

Turn the
ment.

cam so

that the breaker

adjust

points are closed and check the align

To

spring tension (Fig.

14). Align the breaker points to make full face contact by bending the stationary breaker point
(Fig.

17), disconnect the primary and con denser leads at the breaker point
assembly primary terminal. Loosen
the nut

play

with

feeler

gauge

placed

be

tween

the

centrifugal

advance

bracket (Fig. breaker

or
arm.

15). Do

not

bend the
points
adjust

After the breaker

holding

the spring

in position,

plate and the end

top

of the

stop bushing. The

then

move

the

have been properly aligned, gap

dwell.
POINT

the

breaker
and

arm pivot

spring toward the to decrease tension

inch. If the
the collar.

in the

opposite

direction to in

be from 0.022-0.030 play is not to specifications, check the location of

play
should shaft end

BREAKER

SPRING

TENSION

crease

tension.

Correct breaker
sion

point

spring ten
engine
point

then check

Tighten the locknut, the spring tension. Repeat

until

CONDENSER
A capacity test,
a series resistance

is

essential
and

to

proper

the

adjustment

the

specified

operation

normal

breaker

leakage test,

and

spring tension is

obtained.

rapid

life. If the spring tension is too great, wear of the breaker arm rub

primary and condenser lockwasher and tighten the

curely.

Install the leads with the

nut

test should be per

se

can

formed be

on

the condenser. The tests

with

made

the condenser
with

in
the

bing
tard

block

will

result,

causing the

up and re If the spring tension is too weak, the breaker arm will flutter at high speed, resulting in
point

breaker

gap to

close

in the distributor or condenser installed on a test

stalled

the spark timing.

CAM

LOBE
cam

ACCURACY
lobes
will cause

reliable test equipment and

unit. Use follow the

Worn

the cor
out of

responding

cylinders

to

fire

an engine miss at

high

rpm.

time and result

place

in

loss

of power. on a test set

instructions of the manufacturer. The capacity is 0.21-0.25 microfarads, leakage should not be greater than 5

To
gauge

check

the spring

tension,

Install the distributor

and check

the hooked end of the spring tension

over

the accuracy of the cam

the

movable

breaker
right

lobes

following

the

instructions

of

point, then pull the gauge at a

angle

the manufacturer.

If the test indicates

replace the cam.

temperature, and be 1 ohm or less. The condenser should be re placed if it does not meet the above
room series resistance
.should

megohms

at

(90)

to

the

movable

arm

that any lobe

is worn,

specifications.

DISTRIBUTOR OVERHAUL
The
block.
DESCRIPTION

dual

advance

distributor

is

systems. advance

governor-type centrifugal

cam to advance or move ahead with respect to the

mounted

at the

front

of the cylinder

mechanism

is located below
plate

distributor drive breaker

points

shaft.

the

movable

breaker

(Fig. 19),

This
and

action

causes the cam

to open
earlier.
means

and a vacuum operated spark control

close the

AND OPERATION

diaphragm is located
the distributor

on

the side of

The
of
a

weights turn the cam

by

The distributor (Fig. 1 8) has two in

base (Fig. 20).

weights

dependently

operated

spark

advance

The

centrifugal

cause

the

stop plate that has two slots which fit over pins in the weights. The

PART

2 IGNITION

SYSTEM

1-53

PRIMARY TERMINAL
BREAKER PLATE
DIAPHRAGM LINK RETAINER

LUBRICATING WICK DISTRIBUTOR SHAFT

CAM ASSEMBLY
WEIGHT SPRING

CONDENSER
PRIMARY WIRE

WEIGHT

WEIGHT

STATIONARY BREAKER POCNT

ADVANCE

ADVANCE

ADJUSTING ADJUSTMENT SLOT

BREAKER ARM
BRACKET

ADJUSTING
BRACKET

WEIGHT SPRING

STOP PLATE

GROUND WIRE

STOP PLATE
CONDENSER WIRE

11

40- A

CONTROL SLOT

11 30- A

FIG.

18 Dual Advance Distributor

FIG.

19 Centrifugal Advance Mechanism

DISTRIBUTOR CAP

COIL

HIGH

TENSION WIRE

CONDENSER

TERMINAL

ROTOR BREAKER POINTS

DIAPHRAGM

CAM

DIAPHRAGM

SPARK VACUUM PASSAGE

BREAKER PLATE

TO DISTRIBUTOR

1757-A

FIG.
RETURN

21 Vacuum Advance Controls

SPRING

1131-A

FIG.
slots

20 Vacuum Advance Mechanism

determine the
maximum amount

phragm of

to move against the tension to

the

sage

opening,

in the carburetor, is

of advance and

the rate of advance

calibrated springs.
advance mechanism

the spring. This action causes the

plate advance and

in

controlled

by

breaker

the closed throttle plate, there is no vacuum to the diaphragm. The

above

The has

vacuum

points open and

close earlier.

breaker
position

plate

is held in
the

retarded
return

a spring-loaded
which

diaphragm (Fig.
to the breaker

21)

is

connected

The spring loaded side of the diaphragm is air tight and is con nected through a vacuum line to the When the carburetor throttle bore. distributor the plates throttle open,
plate. vacuum passage

When the a light load, quired for

engine

is

operated under

by

calibrated
against

additional advance

is

re

spring

which

bears

the

dia
there
there

maximum

part

throttle
con

phragm.

power and economy.

Under this

dition,
high

engine

manifold

vacuum

is

enough

to actuate the diaphragm

is is

During acceleration or when a heavy load on the engine,

not enough vacuum and

to actuate the

and advance the spark.

speeds or at

At low

engine

diaphragm,
once again

the

breaker

plate

is

exposed causes

to mani the dia-

idle,

a retarded spark

is

is held in

a retarded posi

fold

vacuum

which

necessary.

Because the

vacuum

pas

tion.

1-54

GROUP 1-POWER PLANT

Arbor Press Ram

ToolT52L-12390-CAD

Detail 1

1756-

1763- A

FIG.

22 Gear Pin Removal

or

Installation

FIG.

23 Gear Removal
loosened

under a
road at

When the engine is being operated light load, such as on a level

40 mph,
and

assembly.

by

soaking,

scrub

the parts
not use abrasive

4. Remove

the

lubricating

wick

with a soft a
wire

bristle brush. Do
or
other

the throttle is

from the

cam

assembly, then remove

brush, file

suddenly opened further, the mani fold vacuum will decrease and the

the cam assembly retainer. Remove the cam assembly and the upper
thrust washer.

object.

Dry

the parts with compressed

air.

Be

diaphragm spring will quickly force the breaker plate to a retard position.

moved unhook

all foreign matter is re from the ball bearings on the

sure

5.

Carefully

and

remove

breaker

plate

assembly.

However,
the
unchanged
changes.

the

advance

provided

by

the distributor weight springs. If the

two springs are not the same size or
are and

centrifugal

mechanism

remains

Examine the bushing the distributor shaft and

for
wear.

surface

of

the

bushing
is

until

the

engine

speed
engine

any particular speed, there will be a certain

vacuum advance.

At

different colors, mark the springs the brackets to which they are

The

minimum at

allowable

amount

attached.

This

will eliminate

bending
desig

diameter 0.4675 inch. The

shaft

the

bushing

maximum allowable

of centrifugal advance plus a possible

the

brackets to The

obtain the correct ad

are

vance.

weight springs

DISTRIBUTOR
1. Disconnect
and

REMOVAL
primary wire advance line at the
remove

nated primary (low speed) and sec ondary (high speed). The secondary

inside diameter of the bushing is 0.4690 inch. Replace worn parts. Inspect the distributor cam lobes for scoring and signs of wear. If any lobe is scored or worn, replace the
cam
assembly. plate

the

spring

is

the

spring

which

is

not

the vacuum
and

under tension.

distributor,
tor cap.

the distribu

6. If the
used

gear and mark

shaft are

to be

Inspect the breaker for

plate signs

again,

the

gear and shaft can

of
etc.

2. Scribe

a mark on

the distributor

distortion,
Replace
point

worn

assembly ball

so

that the

pin

holes

body
scribe

and engine

block

be easily
the

indicating

the

bearings,
The
ever

the

breaker
and

aligned

for
pin

assembly.

Remove

position of the another

body
mark

in the block, and on the distribu

the
position of

assembly if it is defective.

gear

roll

(Fig.

22),

then remove

breaker

assembly
replaced

the gear (Fig. 23).

condenser should
shaft collar roll pin

be

when

tor the

body indicating
rotor.

7. Remove the
place

These

marks

can

as guides when

installing

the

be used distribu
hold

the distributor
all

is

overhauled.

(Fig. 24). Invert the distributor

and

Inspect

electrical

wiring

for

it

on a support plate will

allow

tor

in

3.

a correctly timed engine. Remove the distributor

tion
shaft

that

the

in a posi distributor

fraying, breaks,
that are not

etc., and replace any

good condition.

in

to clear the support plate, then

the shaft out of the collar and

down cap screw and clamp, then lift the distributor out of the block.

Check the distributor base for

cracks, stripped threads, or other

press

the distributor
move

housing

(Fig. 25). Re
shaft

damage. Check the diaphragm hous

DISTRIBUTOR
1.
the

DISASSEMBLY

the

distributor

bushing
AND
as

(Fig. 26).

diaphragm

Remove the spring clip securing link to the breaker

DISTRIBUTOR

CLEANING

plate, then disconnect the

diaphragm

INSPECTION
Soak
point uum

ing, bracket, and rod for damage. Check the mounting hole and vacuum line fitting threads for stripping or other damage. Test the vacuum fit
diaphragm for leak under "Distributor Tests, Adjustments, and Minor Re Replace all defective parts.
tings, case,
as
and age

assembly
and

from the distributor base remove the diaphragm assembly.

all parts of the

distributor

sembly (except the condenser, breaker

assembly,

explained

2. Remove the nut, flat washer, and bushing from the primary termi
nal

lubricating

wick, vac terminal

electrical

pair."

screw, then remove the terminal

and

diaphragm, primary bushing and insulator, and

in
a mild

screw

insulator.

wiring)
mineral

sembly
two

3. Remove the breaker point as and condenser. Remove the

screws and retainers

spirits.

cleaning solvent or Do not use a harsh

securing the

cleaning solution. Wipe all parts that can not be immersed in a solvent with
a clean

breaker

plate

ing,

then

assembly in the hous remove the breaker plate

dry

rag.

DISTRIBUTOR ASSEMBLY Refer to Fig. 27 for the correct location of parts. 1. Oil the new bushing, and install it on the bushing replacer tool, then install the bushing (Fig. 28). When
the tool

After foreign deposits have been

bottoms

against

the distribu-

PART

2 IGNITION

SYSTEM

1-55

Arbor

Press Ram

Too/-T52L-I2l3J-CAD
17S5-A

FIG.

24 Shaft Collar Roll

Pin Removal

or

Installation

Tooi-J2I32-B7

or

BUSHING

Too/-T58P-J2l32-B

FIG.
599-A

25 Shaft Removal

FIG.

26 Bushing Removal

NUT
PRIMARY WIRE

WASHER

INSULATOR CLAMP GROUND WIRE

RIVET */

BUSHING

p|N

OILER
-*-

DRIVE GEAR GE/

SHAFT ASSEMBLY
WEIGHT
BREAKER

SCREW

SCREW

POINT

DISTRIBUTOR HOUSING

<^
* m-**

ASSEMBLY

COLLAR
""

I^
X

CAM ASSEMBLY
RETAINER INSULATOR

**% ^5?JJ*
bush,No
DIAPHRAGM yx
<

RIVET

"^

*V^ CLAMP
STOP
GASKfT

L/V

CONDENSER

/
SCREW
BREAKER

*V \

^ ^8)
WICK

\v^L^WE,GHT

scrIw

linkcsl;r,ng CLIP

xx

X>

niAPMDAr.M HOUSING Mnn<;iKir, RETAINING pftainikj^ SCREW srPFW DIAPHRAGM

|j

*w
/
SPRING

LUBRICATING

DIAPHRAGM HOUSING

VACUUM

CAM

UPPER THRUST WASHER

DIAPHRAGM RETURN

CONNECTION
1752-A

PLATE

ASSEMBLY

CALIBRATION WASHER

FIG.

27 Distributor Assembly

1-56

GROUP 1-POWER PLANT

Arbor

Press Ram

PRESS ON

DISTRIBUTOR
BASE

Tool-T58P-12132-B

1577-A
Tool-T 571-1 21
20- A

FIG.

29 Burnishing Bushing

1753-A

FIG.
tor
to

28 Bushing Installation

base,
the

the

bushing

will

correct

depth.
shaft

be installed Burnish the

29).
are gear

ugal
and

advance

the

top

of

adjusting bracket plate the bushing. Tighten

the tool enough

stall

the

wick

in

the

cam

assembly

(Fig. 32). 5. Clean the breaker

as
plate

bushing

to the proper size (Fig.

old
and

the

backing

screw on

bearings

2. If the

to remove all shaft end play.

previously

explained,

then

lubri
engine

being installed,
it into
collar

oil the shaft and slide

the distributor body.

Place the
shaft and

in

position

on

the

align the

holes in the

collar and shaft,

then install a new pin (Fig. 24). Check the shaft end play with a
placed vance

in position and sup port the shaft. While holding the col lar in position against the distributor housing drill a '/s-inch hole through the shaft using the access hole in the
Place the
collar
collar as a pilot.

cate
oil.

them with

S.A.E.
new

10W
plate.

Install the breaker

6. Install a breaker point

ground wire

condenser

and

assembly.

Install

the

on

the

breaker

point

feeler

gauge

Install the

pin

(Fig.

between

the

centrifugal

ad

top
not

of the

adjusting bracket plate and the bushing. If the end play is

supporting tool and the 0.022-inch feeler gauge still in

stalled, install the

24).

With

the

attaching screw furthest from the breaker point adjustment slot. Install
the breaker plate
the ground wire
retainers.

Be

sure

drive

gear

(Fig. 30).
press

lug

is

attached to the

within

limits (0.022-0.030 inch),

gear

Remove the assembly from the

and

breaker

plate retainer

attaching
and

screw.

replace

the shaft.
on

remove the

Press the

the shaft

(Fig.

feeler

gauge.

supporting tool and Drill a '/s-inch hole

Install the primary

sulator on

wire

the

in

the terminal screw.

and

30), using
and
shaft

the marks made on the gear

as guides gear

through the gear and shaft, using the

the

bushing
with

Install terminal screw in

then secure
washer and

to align the pin

hole in the
Install

gear shoulder as a pilot.

the distributor
place

base,
flat

it in
nut.

holes. Check the

sion.

location dimen

a new pin

(Fig. 22).
and springs,
weight pivot

the

With

pushed

play removed (gear toward the distributor base),

all end

3. Install the
then
pin

weights

7. Position the diaphragm

assem

fill the
with
a

groove

in the

bly

and

hook the diaphragm link

on

over

be 5.1 1 1-5.1 16 inches from the bottom face of the gear to the bottom face of the dis
this dimension should
tributor
stall the

bearing
bracket
tion
are

high melting point ball lubricant. If a spring and

marked

the pin the link

the

breaker

plate.

Secure

were

for identifica
sure

retaining

mounting pad (Fig. 30). In pin (Fig. 22)

upon

disassembly, be
together.

they
of

spring retainer. Se diaphragm assembly to the distributor base.

with the cure

the

assembled

8. Align the breaker points,

the

adjust

The

shaft and gear are replaced as

4. Lubricate the inside diameter

the cam assembly with a
point

an assembly.

One

part should not

be

replaced without

replacing the
and gear are
new

other.

ball

bearing

high melting lubricant. Install the

with the

tension, and adjust the breaker points. Install the distributor spring
on a test set, check the

breaker

point

If

new oil

shaft

being
slide

upper

thrust washer, then install the

dwell

and

resistance,

and

adjust

the

installed,

the

shaft

and

cam and secure

it

spring

re

centrifugal and

vacuum advance.

it into the distributor body. Attach the Distributor Shaft Supporting Tool
to the distributor and
place

tainer.
are

Be
a

sure the pins on the weights

slots on

in the

the

the assem
a

Apply
with

light film

of cam

stop plate. lubricant

DISTRIBUTOR

INSTALLATION

bly

in

a press

(Fig. 31). Insert

0.022

to the cam lobes. Saturate the wick

The distributor installation is shown in Fig. 33.

1. If the
crankshaft
was

inch feeler

gauge

between the

centrif

S.A.E. 10W

engine

oil, then in

rotated

PART

2 IGNITION

SYSTEM

1-57

NEW SHAFT WITH 0.022 Too/-T57L- J 2390-A INCH FEELER IN

PLACE,

Detail 5

Tool-T57L-l 2390-A,
Detail 3

TIGHTEN SCREW TO

REMOVE END PLAY

1322-B

FIG.

31 New Shaft Installation

Tool-T57Ll 2390-A, Detail 1

1751-A

FIG.

30 Gear Installation

while the distributor was removed from the engine, it will be necessary to retime the engine. Turn the engine until No. 1 piston is on T.D.C. after

the

compression

stroke.

Align

the

T.D.C.

mark on the crankshaft

dam

per with

the

timing

distributor

with

the rotor at the

firing
open.

position and

Install the No. 1 the breaker points

pointer.

1164-A

FIG.
crankshaft

32 Weights, Springs,

and

Cam Installed

has not been dis turbed, install the distributor using

the
marks

If the

previously

scribed

on the

distributor
guides.

body
the

and engine

block

as

pump intermedi properly engages the dis tributor shaft. It may be necessary to
sure oil
ate

Make

shaft

crank

the

engine with

the starter,
gear
engage

after

the distributor drive

engaged, in
order

is partially
the
oil

to

pump intermediate shaft. 2. Install the rotor and the dis

tributor cap.

Connect the
tension

coil to

dis
and

tributor cap high

connect

lead,
at

the primary wire

the dis

tributor.

3. Check the ignition timing with timing light and adjust it if neces Connect the
the
vacuum with advance

sary.
check

the

line, and timing

light

when the engine

is

accelerated.

FIG.

33 Distributor Installation

1-58

GROUP 1-POWER PLANT

Section

Page

Section

Page and

Trouble

Shooting

1-58

5 Fuel Pumps Booster

6 Fuel Tank

Vacuum
1-72

PART 3

2 Air Cleaner 3 Carburetor

4 Throttle Linkage
..

1-59
1-60

FUEL SYSTEM

and

Lines

1-75

Adjustments

1-72

//

the cause of engine trouble

traced to the

The

causes

of the

trouble

are

has been

fuel

sys

listed in
able

the order of their

prob

TROUBLE SHOOTING

(page 1-7), refer to the trou ble in Table 1 and check the items listed under the trouble.
tem

occurrence;
should

therefore
checked

the the

items
order

be

in

listed.

TABLE 1

Fuel System Trouble

Shooting

AUTOMATIC
engine open. gine

CHOKE.

Check

If the fuel is reaching the

retor, the trouble is

carbu

the position of the choke plate. If the

in the

carburetor.

If the

is warm, the plate should be plate is not open, the en load up due to the
exces

times.
ated

Work the throttle by hand several Each time the throttle is actu fuel
should spurt

will

from the

accel

sively

rich mixture and will not start.

If the

engine

be

closed.

If the

is cold, the plate should plate is not operating

erating pump discharge

nozzles.

If fuel is discharged
erating pump, the

by

the

accel

properly,

check the

following

items:

The

choke

linkage for binding.

cam

flooded,

or

is probably there is water in the fuel

engine mechanical

system, or an engine
such as valves ad

item,

The fast idle

Thermostatic

for binding.

is

at

fault.

spring

housing
for

If fuel is

not

discharged
check:

by

the ac

justment.
Fast idle
speed screw proper ad

celerating pump,

ENGINE

CRANKS

justment

and operation. plate

ball
proper

The accelerating pump discharge check for sticking.

The accelerating pump discharge discharge holes for clogged

NORMALLY, BUT
WILL NOT START

Choke
eration.

valve

for

op

screw and

Choke

air

and choke

heat chamber, air line, housing for air leaks. CARBU

carburetor

passages.

The accelerating pump diaphragm for defects.

FUEL SUPPLY AT RETOR. Disconnect the

fuel inlet line Crank the

at

the carburetor. Use to catch the fuel. to see

check

a suitable container engine

The accelerating pump inlet ball for freeness and inlet passages for dirt, corrosion, etc.
The fuel inlet
system

if fuel is
carbu

reaching the If fuel is

retor, check:

including,
float

the

carburetor.
not

fuel inlet screen, the fuel inlet

and

needle as

reaching the

seat

assembly, and the

sembly.

The fuel

pump.

The fuel pump flexible inlet line for a collapsed condition.

Check for dirt in the carburetor, allowing fuel to enter or be dis charged from the idle system.
not

Idle fuel

mixture needles not

prop

Fuel

inlet

system

not

operating
or car

ENGINE

STARTS,

erly

adjusted.

properly.

BUT FAILS

Engine idle The

speed set

too low.
properly.

Dirt

or water

in fuel lines

buretor.
operating

TO

KEEP RUNNING

choke not

Carburetor icing.
Fuel pump defective.

Float setting incorrect.

LITHO

IN U.S.A.

FORM 7750-58